Model DSP6001 User's Manual - magtrol.com · i 1. Make sure that all Magtrol dynamometers and electronic products are earth-grounded, to ensure personal safety and proper operation

Model DSP6001

High Speed ProgrammableDynamometer Controller

User’s Manual

1st Edition, revision J – March 2010

While every precaution has been exercised in the compilation of this document to ensure the accuracy of its contents, Magtrol, Inc. assumes no responsibility for errors or omissions. Additionally, no liability is assumed for any damages that may result from the use of the information contained within this publication. COPYRIGHTCopyright ©2001-2010 Magtrol, Inc. All rights reserved.Copying or reproduction of all or any part of the contents of this manual without the express permission of Magtrol is strictly prohibited.

TRADEMARKSLabVIEW™ is a trademark of National Instruments Corporation.Microsoft® is a registered trademark of Microsoft Corporation.National Instruments™ is a trademark of National Instruments Corporation.Windows® is a registered trademark of Microsoft Corporation.

Purchase Record

Please record all model numbers and serial numbers of your Magtrol equipment, along with the general purchase information. The model number and serial number can be found on either a silver identification plate or white label affixed to each unit. Refer to these numbers whenever you communicate with a Magtrol representative about this equipment.

Model Number: _____________________________

Serial Number: _____________________________

Purchase Date: _____________________________

Purchased From: _____________________________

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1. Make sure that all Magtrol dynamometers and electronic products are earth-grounded, to ensure personal safety and proper operation.

2. Check line voltage before operating the DSP6001.

3. Make sure that dynamometers and motors under test are equipped with appropriate safety guards.

Safety Precautions

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The contents of this manual are subject to change without prior notice. Should revisions be necessary, updates to all Magtrol User’s Manuals can be found at Magtrol’s web site at www.magtrol.com/support/manuals.htm.

Please compare the date of this manual with the revision date on the web site, then refer to the manual’s Table of Revisions for any changes/updates that have been made since this edition.

REVISION DATE

1st Edition, revision J – March 2010

TABLE OF REVISIONS

Revisions To This Manual

Date Edition Change Section(s)03/01/10 1st Edition - rev. J Added 60 bit encoder to chart for torque transducers 3.3.104/16/09 1st Edition - rev. I Added UE commands 5 = 1-bit, 6 = 2-bit and 7 = 6-bit. 8.6.405/18/05 1st Edition - rev. H Changed M-TEST 4.0 references to “M-TEST” or “M-TEST 5.0” throughout

manual06/28/04 1st Edition - rev. G Removed DSP6001 resetting procedure 9.405/24/04 1st Edition - rev. F Added DIR#, OH1 and IOXX.XX Misc. Command codes 8.6.7, D.608/05/03 1st Edition - rev. E Ratings changes for: Operating Temperature, Accuracy,

Temperature Coefficient and Accessory Torque/Speed Output1.3

08/05/03 1st Edition - rev. E Auxiliary Input rating replaced with Input Voltage Range 1.308/05/03 1st Edition - rev. E Screen Saver function removed 2.3.208/05/03 1st Edition - rev. E Added Power Alarm to priority table 6.1.308/05/03 1st Edition - rev. E Deleted DDLXX.XX Ramp Command code 8.6.3, D.308/05/03 1st Edition - rev. E Deleted A,B,C,D and E Speed Command codes 8.6.3, 8.6.5, D.308/05/03 1st Edition - rev. E Deleted C# Misc. Command code 8.6.7, D.605/06/02 1st Edition - rev. D Speed check and decimal point check added to calibration

procedure9.3.5 & 9.3.6

12/20/01 1st Edition - rev. C Added values for analog filter setup (AF1# and AF2#) 8.6.412/20/01 1st Edition - rev. C Added filter cutoff frequency 4.108/27/01 1st Edition - rev. B Changed name of chapter titles Chap. 7 & 808/27/01 1st Edition - rev. B Changed name and location of Additional Scale Factor Table Appendix F08/27/01 1st Edition - rev. B Updated Power Analyzers in System Options table 1.307/23/01 1st Edition - rev. A Updated Motor Testing Software section and System Options 1.307/23/01 1st Edition - rev. A Increased range of PID numbers when using the multiplier 5.407/23/01 1st Edition - rev. A Changed Contact Configuration and Manufacturer P/N under

Relay Specifications6.1.1

07/23/01 1st Edition - rev. A Air Flow Alarm for Eddy-Current/Powder Brake Dynamometers is not available

6.1.3

07/23/01 1st Edition - rev. A Changed IDN? command to *IDN? command 8.607/23/01 1st Edition - rev. A Added alarm condition to explanation of OD command 8.607/23/01 1st Edition - rev. A Entered exact figures for reference voltage 9.3.2, 9.3.307/23/01 1st Edition - rev. A Defined accepted voltage range in steps 3, 6, 9 & 14 9.3.403/27/01 1st Edition Complete re-write of Preliminary Manual entire manual

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Table of Contents

SAFETY PRECAUTIONS ......................................................................................................................... I

REVISIONS TO THIS MANUAL ............................................................................................................... IIREVISION DATE ................................................................................................................................................................. II

TABLE OF REVISIONS ...................................................................................................................................................... II

TABLE OF CONTENTS .......................................................................................................................... IIITABLE OF FIGURES ........................................................................................................................................................VII

PREFACE ................................................................................................................................................ IXPURPOSE OF THIS MANUAL ......................................................................................................................................... IX

WHO SHOULD USE THIS MANUAL .............................................................................................................................. IX

MANUAL ORGANIZATION ............................................................................................................................................. IX

CONVENTIONS USED IN THIS MANUAL ..................................................................................................................... X

1. INTRODUCTION ................................................................................................................................ 11.1 UNPACKING YOUR DSP6001 ..................................................................................................................................... 1

1.2 NEW FEATURES OF THE DSP6001 ........................................................................................................................... 1

1.3 DATA SHEET ................................................................................................................................................................. 2

2. CONTROLS ......................................................................................................................................... 82.1 FRONT PANEL .............................................................................................................................................................. 8

2.2 FRONT PANEL CONTROLS AND BUTTONS ........................................................................................................... 82.2.1 Enabling Secondary Functions ......................................................................................................................... 82.2.2 Enabling Saving Function ................................................................................................................................ 92.2.3 How to Use Front Panel Controls and Buttons ................................................................................................ 9

2.3 VACUUM FLUORESCENT DISPLAY (VFD) ........................................................................................................... 102.3.1 Contrast Settings ............................................................................................................................................ 112.3.2 Screen Saver ................................................................................................................................................... 112.3.3 Status Display Messages ................................................................................................................................ 11

2.4 REAR PANEL .............................................................................................................................................................. 12

2.5 REAR PANEL INPUTS AND OUTPUTS................................................................................................................... 12

3. INSTALLATION/CONFIGURATION .................................................................................................. 153.1 POWERING UP THE DSP6001 .................................................................................................................................. 15

3.1.1 Setting Unit for Line Voltage ......................................................................................................................... 153.1.2 Self-Test ......................................................................................................................................................... 163.1.3 Main Menu ..................................................................................................................................................... 16

3.2 TESTING INSTRUMENTATION SETUP .................................................................................................................. 173.2.1 Dynamometer Configuration Menu ............................................................................................................... 183.2.2 Hysteresis Dynamometer Setup ..................................................................................................................... 193.2.3 Hysteresis Dynamometer with Torque Transducer Setup .............................................................................. 203.2.4 Hysteresis Dynamometer with Auxiliary Instrumentation Setup................................................................... 223.2.5 Hysteresis Dynamometer with Eddy-Current or Powder Brake Setup .......................................................... 243.2.6 Eddy-Current or Powder Brake Dynamometer Setup .................................................................................... 263.2.7 Eddy-Current or Powder Brake Dynamometer with Torque Transducer Setup ............................................. 273.2.8 Eddy-Current or Powder Brake Dynamometer with Auxiliary Instrumentation Setup ................................. 283.2.9 Two Eddy-Current/Powder Brake Dynamometers (Independent Setup) ....................................................... 293.2.10 Two Eddy-Current/Powder Brake Dynamometers (Tandem Setup) .............................................................. 313.2.11 Eddy-Current Dynamometer with Powder Brake Dynamometer (Tandem Setup) ........................................ 333.2.12 In-Line Torque Transducer Cross Loop Function .......................................................................................... 35

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Magtrol Model DSP6001 Dynamometer ControllerTable of Contents

3.3 SPEED ENCODER SETUP ......................................................................................................................................... 363.3.1 Bit Configurations .......................................................................................................................................... 36

3.4 TORQUE/SPEED ANALOG OUTPUTS .................................................................................................................... 373.4.1 Torque DAC Scale Factor ............................................................................................................................... 373.4.2 Speed DAC Scale Factor ................................................................................................................................ 373.4.3 Torque/Speed DAC Setup .............................................................................................................................. 37

4. DIGITAL FILTERS ............................................................................................................................. 384.1 FILTER PARAMETERS ............................................................................................................................................. 38

4.2 FILTER SETUP ............................................................................................................................................................ 39

5. PID SETTINGS .................................................................................................................................. 405.1 ABOUT THE PID LOOP ............................................................................................................................................. 40

5.1.1 P (Proportional Gain) ..................................................................................................................................... 405.1.2 I (Integral) ...................................................................................................................................................... 405.1.3 D (Derivative) ................................................................................................................................................. 40

5.2 SETTING PID VALUES .............................................................................................................................................. 405.2.1 How To Set P (Proportional Gain) Value ....................................................................................................... 405.2.2 How to Set I (Integral) Value .......................................................................................................................... 405.2.3 How to Set D (Derivative) Value .................................................................................................................... 40

5.3 HOW THE PID LOOP WORKS .................................................................................................................................. 415.3.1 Scale Factors for Hysteresis, Eddy-Current and Powder Brake Dynamometers ........................................... 415.3.2 Speed Correction for WB (Eddy-Current Brake) Dynamometer ................................................................... 415.3.3 Equations ........................................................................................................................................................ 42

5.4 ADDITIONAL SCALE FACTOR ............................................................................................................................... 425.4.1 How To Set Additional Scale Factor .............................................................................................................. 42

5.5 SETTING THE CORRECT PID’S FOR YOUR MOTOR .......................................................................................... 435.5.1 Setting the PID with an Unknown Motor or System ..................................................................................... 435.5.2 Setting the PID for Torque Control ................................................................................................................ 435.5.3 Setting the PID for Speed Control ................................................................................................................. 465.5.4 Setting the PID for Ramp Down .................................................................................................................... 48

6. ALARM SYSTEM .............................................................................................................................. 506.1 GENERAL INFORMATION ....................................................................................................................................... 50

6.1.1 Alarm Relay ................................................................................................................................................... 506.1.2 Alarm Operation............................................................................................................................................. 516.1.3 Alarm Priority ................................................................................................................................................ 52

6.2 POWER ALARM ......................................................................................................................................................... 526.2.1 Instructions for Power Alarm Setup ............................................................................................................... 526.2.2 Power Alarm Action ....................................................................................................................................... 536.2.3 To Reset Power Alarm .................................................................................................................................... 53

6.3 MAXIMUM SPEED ALARM .................................................................................................................................... 536.3.1 Instructions for Maximum Speed Alarm Setup .............................................................................................. 536.3.2 Maximum Speed Alarm Action ...................................................................................................................... 546.3.3 To Reset Maximum Speed Alarm .................................................................................................................. 54

6.4 MAXIMUM TORQUE ALARM ................................................................................................................................ 546.4.1 Instructions for Maximum Torque Alarm Setup ............................................................................................ 546.4.2 Maximum Torque Alarm Action .................................................................................................................... 556.4.3 To Reset Maximum Torque Alarm ................................................................................................................. 55

6.5 AIR FLOW ALARM .................................................................................................................................................... 566.5.1 Instructions for Air Flow Alarm Setup ........................................................................................................... 566.5.2 Air Flow Alarm Action ................................................................................................................................... 566.5.3 To Reset Air Flow Alarm ............................................................................................................................... 56

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Magtrol Model DSP6001 Dynamometer Controller Table of Contents

6.6 WATER FLOW ALARM ............................................................................................................................................. 576.6.1 Instructions for Water Flow Alarm Setup ....................................................................................................... 576.6.2 Water Flow Alarm Action .............................................................................................................................. 576.6.3 To Reset Water Flow Alarm ........................................................................................................................... 57

6.7 EXTERNAL ALARM .................................................................................................................................................. 586.7.1 Instructions for External Alarm Setup............................................................................................................ 586.7.2 External Alarm Action.................................................................................................................................... 586.7.3 To Reset External Alarm ................................................................................................................................ 58

6.8 TEMPERATURE ALARM .......................................................................................................................................... 596.8.1 Instructions for Temperature Alarm Setup ..................................................................................................... 596.8.2 Temperature Alarm Action ............................................................................................................................. 596.8.3 To Reset Temperature Alarm .......................................................................................................................... 59

6.9 ELECTRICAL ALARM .............................................................................................................................................. 606.9.1 Instructions for Electrical Alarm Setup .......................................................................................................... 606.9.2 Electrical Alarm Action .................................................................................................................................. 606.9.3 To Reset Electrical Alarm .............................................................................................................................. 60

7. MANUALLY CONTROLLED OPERATION ....................................................................................... 617.1 HOW TO CHOOSE DESIRED CHANNEL WHEN USING TWO DYNAMOMETERS ......................................... 61

7.2 HOW TO SET DESIRED POWER UNITS ................................................................................................................ 62

7.3 HOW TO SET DESIRED TORQUE UNITS .............................................................................................................. 62

7.4 HOW TO SET TORQUE CONTROL .......................................................................................................................... 62

7.5 HOW TO SET SPEED CONTROL ............................................................................................................................. 63

7.6 HOW TO SET OPEN LOOP CONTROL .................................................................................................................... 64

8. COMPUTER CONTROLLED OPERATION ...................................................................................... 658.1 ABOUT THE GPIB INTERFACE ............................................................................................................................... 65

8.1.1 Installing the GPIB (IEEE-488) Connector Cable ......................................................................................... 658.1.2 Changing the GPIB Primary Address ............................................................................................................ 66

8.2 ABOUT THE RS-232 INTERFACE ............................................................................................................................ 668.2.1 Connection ..................................................................................................................................................... 668.2.2 Communication Parameters ........................................................................................................................... 678.2.3 Baud Rate ....................................................................................................................................................... 67

8.3 CHECKING THE DSP6001-TO-PC CONNECTION ................................................................................................. 67

8.4 DATA FORMAT ........................................................................................................................................................... 68

8.5 PROGRAMMING ....................................................................................................................................................... 688.5.1 Data Termination Characters .......................................................................................................................... 688.5.2 Timeout .......................................................................................................................................................... 69

8.6 DSP6001 COMMAND SET ........................................................................................................................................ 698.6.1 Alarm Commands .......................................................................................................................................... 698.6.2 Communication Commands ........................................................................................................................... 708.6.3 Ramp Commands ........................................................................................................................................... 718.6.4 Setup Commands ........................................................................................................................................... 728.6.5 Speed Commands ........................................................................................................................................... 748.6.6 Torque Commands ......................................................................................................................................... 748.6.7 Miscellaneous Command ............................................................................................................................... 75

9. CALIBRATION .................................................................................................................................. 769.1 CLOSED-BOX CALIBRATION ................................................................................................................................. 76

9.2 CALIBRATION SCHEDULE ...................................................................................................................................... 76

9.3 BASIC CALIBRATION PROCESS ............................................................................................................................. 769.3.1 Initial Calibration Procedure .......................................................................................................................... 76

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9.3.2 TSC1 Offset and Gain .................................................................................................................................... 779.3.3 TSC2 Offset and Gain .................................................................................................................................... 789.3.4 DAC Output Offset and Gain ......................................................................................................................... 789.3.5 Speed Check ................................................................................................................................................... 809.3.6 Decimal Point Check...................................................................................................................................... 81

10. TROUBLESHOOTING ..................................................................................................................... 82

APPENDIX A: LABVIEW PROGRAMMING EXAMPLES ..................................................................... 83A.1 SIMPLE READ ............................................................................................................................................................ 83

A.2 TORQUE STABILIZED .............................................................................................................................................. 84

A.3 SPEED STABILIZED .................................................................................................................................................. 85

APPENDIX B: INERTIA CORRECTION ............................................................................................... 86B.1 INERTIAL EFFECT ON MOTOR TEST DATA ......................................................................................................... 86

B.2 PROCEDURE FOR INERTIA CORRECTION .......................................................................................................... 86B.2.1 Key Conditions ............................................................................................................................................... 87

APPENDIX C: FRONT PANEL/DISPLAY MENU FLOW CHARTS ....................................................... 88C.1 PRIMARY KEY FUNCTIONS.................................................................................................................................... 88

C.2 SECONDARY KEY FUNCTIONS ............................................................................................................................. 89C.2.1 Power Units Menu .......................................................................................................................................... 89C.2.2 Torque Units Menu......................................................................................................................................... 89C.2.3 Max Speed Menu ........................................................................................................................................... 90C.2.4 Aux Setup Menu ............................................................................................................................................ 90C.2.5 Com Setup Menu............................................................................................................................................ 91C.2.6 Dyno Setup Menu .......................................................................................................................................... 92

APPENDIX D: REMOTE CONFIGURATION FLOW CHARTS ............................................................ 101D.1 ADVANCED CONFIGURATION ............................................................................................................................. 101

D.2 PRE-TEST .................................................................................................................................................................. 102

D.3 RAMP ......................................................................................................................................................................... 103

D.4 SPEED ........................................................................................................................................................................ 104

D.5 TORQUE .................................................................................................................................................................... 105

D.6 MISCELLANEOUS ................................................................................................................................................... 106

D.7 DATA .......................................................................................................................................................................... 106

APPENDIX E: SCHEMATICS .............................................................................................................. 107E.1 DYNAMOMETER POWER SUPPLY ....................................................................................................................... 107

E.2 DYNAMOMETER DSP & MEMORY ...................................................................................................................... 108

E.3 DSP DYNAMOMETER ANALOG I/O ..................................................................................................................... 109

APPENDIX F: ADDITIONAL SCALE FACTOR TABLE ....................................................................... 110

INDEX ................................................................................................................................................... 111

SERVICE INFORMATION .................................................................................................................... 114RETURNING MAGTROL EQUIPMENT FOR REPAIR AND/OR CALIBRATION .................................................... 114

Returning Equipment to Magtrol, Inc. (United States) .............................................................................................. 114Returning Equipment to Magtrol SA (Switzerland) ................................................................................................... 114

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Magtrol Model DSP6001 Dynamometer Controller Table of Contents

TABLE OF FIGURES

2. CONTROLSFigure 2–1 Front Panel ..............................................................................................................................................8Figure 2–2 Secondary Function Menu ........................................................................................................................8Figure 2–3 Saving Function Menu ..............................................................................................................................9Figure 2–4 Rear Panel ..............................................................................................................................................12Figure 2–5 Dynamometer Brake Input .....................................................................................................................12Figure 2–6 Accessory Torque-Speed Output .............................................................................................................12Figure 2–7 Dynamometer/TSC1 Connector .............................................................................................................13Figure 2–8 AUX/TSC2 Connector .............................................................................................................................13Figure 2–9 Supply 1 Connector ................................................................................................................................13Figure 2–10 Supply 2 Connector ..............................................................................................................................14Figure 2–11 RS-232C Interface ................................................................................................................................14

3. INSTALLATION/CONFIGURATIONFigure 3–1 Cover for Voltage Selector, Fuses ...........................................................................................................15Figure 3–2 Program Download Display ...................................................................................................................16Figure 3–3 Revision Display .....................................................................................................................................16Figure 3–4 Alarm Warning Display ..........................................................................................................................16Figure 3–5 Main Menu .............................................................................................................................................16Figure 3–6 Dyno Setup Menu ...................................................................................................................................18Figure 3–7 Dynamometer Configuration Menu ........................................................................................................18Figure 3–8 Hysteresis Dynamometer Setup ..............................................................................................................19Figure 3–9 Hysteresis Setup Menu ...........................................................................................................................19Figure 3–10 Hysteresis Dynamometer with Torque Transducer Setup .....................................................................20Figure 3–11 Torque Transducer Setup Menu ............................................................................................................21Figure 3–12 Aux Setup Menu - Display On ..............................................................................................................21Figure 3–13 TSC1 with TM2XX Output Menu ..........................................................................................................21Figure 3–14 Hysteresis Dynamometer with Auxiliary Instrumentation Setup ..........................................................22Figure 3–15 TSC2 Aux Setup Menu ..........................................................................................................................23Figure 3–16 TSC1 with AUX Output Menu ...............................................................................................................23Figure 3–17 Hysteresis Dynamometer with Eddy-Current or Powder Brake Setup .................................................24Figure 3–18 TSC2 Eddy-Current/Powder Brake Setup Menu ..................................................................................25Figure 3–19 Nominal Speed Setup Menu ..................................................................................................................25Figure 3–20 Eddy-Current or Powder Brake Dynamometer Setup ..........................................................................26Figure 3–21 TSC1 Eddy-Current/Powder Brake Setup Menu ..................................................................................26Figure 3–22 Eddy-Current or Powder Brake Dynamometer with Torque Transducer Setup ...................................27Figure 3–23 Eddy-Current or Powder Brake Dynamometer with Auxiliary Instrumentation Setup ........................28Figure 3–24 Two Eddy-Current/Powder Brake Dynamometers (Independent Setup) ..............................................29Figure 3–25 Tandem Configuration Menu ................................................................................................................30Figure 3–26 Two Eddy-Current/Powder Brake Dynamometers (Tandem Setup) .....................................................31Figure 3–27 Eddy-Current Dynamometer with Powder Brake Dynamometer (Tandem Setup) ...............................33Figure 3–28 TSC1 Eddy-Current Setup Menu ...........................................................................................................33Figure 3–29 TSC2 Powder Brake Setup Menu ..........................................................................................................34Figure 3–30 Maximum Speed Excited Menu ............................................................................................................34Figure 3–31 In-Line Torque Transducer Cross Loop Function ................................................................................35Figure 3–32 Brake Type Menu ..................................................................................................................................35Figure 3–33 Brake Type Menu (for WB) ...................................................................................................................36Figure 3–34 Encoder Menu ......................................................................................................................................36Figure 3–35 Torque/Speed DAC Setup Menu ............................................................................................................37

4. DIGITAL FILTERSFigure 4–1 Transposed Direct Form II Architecture .................................................................................................38

5. PID SETTINGSFigure 5–1 System Block Diagram............................................................................................................................41Figure 5–2 Open Loop Control Menu .......................................................................................................................43Figure 5–3 Initial P Setting for Torque Control at 25% ...........................................................................................44

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Figure 5–4 High Initial P Setting for Torque Control .............................................................................................44Figure 5–5 Initial I Setting for Torque Control .........................................................................................................45Figure 5–6 Initial D Setting for Torque Control .......................................................................................................45Figure 5–7 Initial P Setting for Speed Control at 25% ..............................................................................................46Figure 5–8 Initial I Setting for Speed Control ..........................................................................................................47Figure 5–9 Initial D Setting for Speed Control .........................................................................................................47Figure 5–10 Ramp Down Low I ................................................................................................................................48Figure 5–11 Ramp Down High I ...............................................................................................................................49Figure 5–12 Ramp Down Dynamic I ........................................................................................................................49

6. ALARM SYSTEMFigure 6–1 Normal Condition “Energized Relay” ...................................................................................................50Figure 6–2 Alarm Condition “De-Energized Relay” ...............................................................................................50Figure 6–3 Typical Application .................................................................................................................................51Figure 6–4 Alarm Enable/Disable Menu ..................................................................................................................51Figure 6–5 Max Power Menu ....................................................................................................................................52Figure 6–6 Power Alarm Display .............................................................................................................................53Figure 6–7 Speed Alarm Setup Menu........................................................................................................................53Figure 6–8 -OL- Speed Alarm Display .....................................................................................................................54Figure 6–9 Over Speed Alarm Message Display ......................................................................................................54Figure 6–10 Torque Alarm Setup Menu ....................................................................................................................55Figure 6–11 -OL- Torque Alarm Display ..................................................................................................................55Figure 6–12 Over Torque Alarm Message Display ...................................................................................................55Figure 6–13 Air Flow Alarm Setup Display .............................................................................................................56Figure 6–14 Air Flow Alarm Message Display ........................................................................................................56Figure 6–15 Water Flow Alarm Setup Display .........................................................................................................57Figure 6–16 Water Flow Alarm Message Display ....................................................................................................57Figure 6–17 External Alarm Setup Display ..............................................................................................................58Figure 6–18 External Alarm Message Display .........................................................................................................58Figure 6–19 Temperature Alarm Message Display ...................................................................................................59Figure 6–20 Electrical Alarm Message Display .......................................................................................................60

7. MANUALLY CONTROLLED OPERATIONFigure 7–1 Dynamometer Channel Menu .................................................................................................................61Figure 7–2 Power Units Menu ..................................................................................................................................62Figure 7–3 Torque Units Menu .................................................................................................................................62Figure 7–4 Torque Control Menu ..............................................................................................................................62Figure 7–5 Max Speed Menu ....................................................................................................................................63

8. COMPUTER CONTROLLED OPERATIONFigure 8–1 GPIB Installation ..................................................................................................................................65Figure 8–2 Com Setup Menu Display .......................................................................................................................66Figure 8–3 RS-232 Interface .....................................................................................................................................66Figure 8–4 Straight Through Pin-to-Pin Cable Connection .....................................................................................67

9. CALIBRATIONFigure 9–1 Calibration Display Analog Inputs ........................................................................................................77Figure 9–2 TSC1 Input Connector ............................................................................................................................77Figure 9–3 TSC2 Input Connector ............................................................................................................................78Figure 9–4 Calibration Output DAC Display Menu .................................................................................................78Figure 9–5 Supply 1 Connector ................................................................................................................................79Figure 9–6 Supply 2 Connector ................................................................................................................................79Figure 9–7 Calibration Accessory Torque DAC Display Menu ................................................................................79Figure 9–8 Accessory Torque-Speed Output .............................................................................................................80Figure 9–9 Calibration Accessory Speed DAC Display Menu .................................................................................80

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Preface

PURPOSE OF THIS MANUAL

This manual contains all the information required for the installation and general use of the Model DSP6001 Dynamometer Controller. To ensure proper use of the instrument, please read this manual thoroughly before operating it. Keep the manual in a safe place for quick reference whenever a question arises.

WHO SHOULD USE THIS MANUAL

This manual is intended for bench test operators who are going to use the Model DSP6001 Dynamometer Controller in conjunction with any Magtrol Hysteresis, Eddy-Current or Powder Brake Dynamometer, Magtrol In-Line Torque Transducer or auxiliary instrumentation.

MANUAL ORGANIZATION

This section gives an overview of the structure of the manual and the information contained within it. Some information has been deliberately repeated in different sections of the document to minimize cross-referencing and to facilitate understanding through reiteration.

The structure of the manual is as follows:

Chapter 1: INTRODUCTION - Contains the technical data sheet for the DSP6001 Dynamometer Controller, which describes the unit and provides its technical characteristics.

Chapter 2: CONTROLS - Description of the elements located on the front and rear panels of the unit.

Chapter 3: INSTALLATION/CONFIGURATION - Provides setup options available with the DSP6001 Dynamometer Controller. Illustrates and outlines the hardware connection setup and software configurations for each option.

Chapter 4: DIGITAL FILTERS - Contains theory and setup information pertaining to Digital Filters.

Chapter 5: PID SETTINGS - Describes the Proportional Integral Derivative (PID) Loop and provides information on theory, setup and use.

Chapter 6: ALARM SYSTEM - Describes the new built-in alarm feature providing the user with information on how each different alarm operates along with instructions for setup and use.

Chapter 7: MANUALLY CONTROLLED OPERATION - How to run a test when the DSP6001 is used as a stand-alone unit. Includes information on setting power and torque units, torque and speed control and open loop control.

Chapter 8: COMPUTER CONTROLLED OPERATION - How to run a test when the DSP6001 is used with a PC. Includes information on GPIB Interface, RS-232 Interface, data format, programming and command set.

Chapter 9: CALIBRATION - Provides recommended calibration schedules along with step-by-step instructions for the calibration procedure.

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Magtrol Model DSP6001 Dynamometer ControllerPreface

Chapter 10: TROUBLESHOOTING - Solutions to common problems encountered during setup and testing.

Appendix A: LABVIEW™ PROGRAMMING EXAMPLES - Magtrol’s comprehensive motor-test software programs, made specifically to compliment the DSP6001 Dynamometer Controller.

Appendix B: INERTIA CORRECTION - Describes the inertial effect on motor test data providing solutions for correction.

Appendix C: FRONT PANEL/DISPLAY MENU FLOW CHARTS - A visual display of various setup procedures.

Appendix D: REMOTE CONFIGURATION FLOW CHARTS - A visual display of the command set used when programming the DSP6001.

Appendix E: SCHEMATICS - For Encoder/Switch Board, Power Supply, DSP & Memory and Analog I/O.

Appendix F: ADDITIONAL SCALE FACTOR TABLE - Provides additional scale factor values based on test instrument selection.

CONVENTIONS USED IN THIS MANUAL

The following symbols and type styles may be used in this manual to highlight certain parts of the text:

Note: This is intended to draw the operator’s attention to complementary information or advice relating to the subject being treated. It introduces information enabling the correct and optimal functioning of the product to be obtained.

Caution : this is used to draw the operator's attention to information, direCtives, proCedures, etC. whiCh, if ignored, may result in damage being Caused to the material being used. the assoCiated text desCribes the neCessary preCautions to take and the ConsequenCes that may arise if the preCautions are ignored.

WARNING! THIS INTRODUCES DIRECTIVES, PROCEDURES, PRECAUTIONARY MEASURES, ETC. WHICH MUST BE EXECUTED OR FOLLOWED WITH THE UTMOST CARE AND ATTENTION, OTHERWISE THE PERSONAL SAFETY OF THE OPERATOR OR THIRD PARTIES MAY BE PUT AT RISK. THE READER MUST ABSOLUTELY TAKE NOTE OF THE ACCOMPANYING TEXT, AND ACT UPON IT, BEFORE PROCEEDING FURTHER.

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Calibration Certificate

1. Introduction

1.2 NEW FEATURES OF THE DSP6001Magtrol’s new Model DSP6001 Dynamometer Controller is an upgraded version of the DSP6000, providing superior motor testing capabilities by using state-of-the-art digital signal processing technology. Designed for use with any Magtrol Hysteresis, Eddy-Current or Powder Brake Dynamometer, Magtrol In-Line Torque Transducer or auxiliary instrumentation, the DSP6001 both controls the dynamometer and provides digital readouts on the front panel. The features that make the DSP6001 unique include:

• TwoChannels-Enablesunittosupportacombinationofuptotwotestinginstrumentswithindependent or tandem configurations.

• Built-InAlarmSystem -Tocaution theuserwhenproblemsoccur, thereareautomaticelectrical and temperature alarms programmed into the unit. Also inherent to the unit are optional power, speed, torque, air flow, water flow and external input alarms that become active when enabled by the user.

• Torque/SpeedAnalogOutputs-Abletointerfacewithadataacquisitionsystemorstripchart recorder.

• DigitalFilter-Removesundesirednoisefromtorquesignals.

• CrossLoopFunction-Allowsclosedloopcontrolofabrakeviathetorquetransducer.

• Saving-Allowsusertosaveprogrammedvalueswithintheirconfigurations.

1.1 UNPACKING YOUR DSP6001Your DSP6001 was packaged carefully for shipping. Please notify your carrier and Magtrol Customer Service if you believe your unit was damaged in shipping.

1. Save all shipping cartons and packaging material until you inspect the DSP6001.

2. Inspect the DSP6001 for any evidence of damage in shipping.

3. Make sure the carton contains the following:

MODEL DSP6001DYNAMOMETER CONTROLLER

POWER

POWER

BRAKE STATUS SET POINT SET POINT P I D

TORQUE SPEED STATUS

DECREASE INCREASE

UPDIP

DYNO SETUP SHIFTCOM SETUPAUX SETUP

SPEED SET

MAX SPEED

TORQUE SET

TORQUE UNITS

BRAKE ON/OFF

POWER UNITS

DOWN

DSP6001 Dynamometer Controller

Line cord

Magtrol User Manual CD-Rom

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Magtrol Model DSP6001 Dynamometer ControllerChapter 1 – Introduction

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1.3 DATA SHEET DSP6001Data Sheet

DSP6001 High-Speed Programmable Dynamometer Controller

1 www.magtrol.com

MAGTROL

FEATURES• Two Channels:Enabletheunittosupportupto

twotestinginstrumentswithindependentortandemconfigurations.

• Built-in Alarm System:Forpower,speed,torque,temperature,airflow,waterflow,electricaloverloadandexternalinputs

• Torque/Speed Analog Outputs:Forinterfacewithadataacquisitionsystemorstripchartrecorder

• Interfaces:RS-232andIEEE-488• High Speed Data Acquisition:120torqueandspeed

pointspersecondviaIEEEbus(approx.60/sec.viaRS-232)

• High Quality, Easy-to-Read Vacuum Fluorescent Readout:Displaystorque,speed,power,auxiliaryandPID(proportionalgain,integralandderivative)values

• Fast Full-Curve Data Acquisition: Free-runtolockedrotorinseconds

• Speed & Torque Operating Modes:ProvideindependentPIDsettingsforimprovedDynamometercontrol

• Built-in Current-Regulated Supply:ForusewithHysteresisDynamometeronly

• Adjustable Torque Units:English,MetricandSIarestandard

• Dynamometer Overload Protection• Digital Filter: Removesundesirednoisefromtorque

signals• Cross Loop Function: Allowsclosedloopcontrolof

brakeviatorquetransducer• Programmable Digital PID Values:Controlledand

storedviaM-TestSoftwareorcontrolledmanually• Saving:Savesprogrammedvalueswithin

configuration• Auxiliary ± 10 V DC Analog Input:Foradditional

transducer• Single or Multi-point Torque and Speed Stabilized

Testing: ViaM-TEST5.0Software• Closed Box Calibration• Rack Mounting: 19"(482.6mm)withhandles

DESCRIPTIONMagtrol’s Model DSP6001 High Speed ProgrammableDynamometer Controller employs state-of-the-art DigitalSignalProcessingTechnologytoprovidesuperiormotortesting

capabilities.Designed forusewith anyMagtrolHysteresis,Eddy-Current or Powder Dynamometer, Magtrol In-LineTorqueTransducerorauxiliaryinstrumentation,theDSP6001canprovidecompletePCcontrolviatheIEEE-488orRS-232interface.With120readingspersecond,theDSP6001isideallysuitedforboththetestlabandtheproductionline.

APPLICATIONSInthelaboratory,theDSP6001’shighsamplerateprovidessuperior resolution for data acquisition and curveplotting.Thisallowsforcapturingmoreusablemotortestdataduringswitching, breakdown and other transitional areas of themotor test curve.Forproduction and incoming inspection,theDSP6001displaystorque,speedandpoweratalltimes,allowingtheControllertobeusedasamanualstandaloneunitoraspartofacompletePCsystem.

MOTOR TESTING SOFTWAREMagtrol’sM-TEST5.0Software(sold separately)isastate-of-the-artmotortestingprogramforWindows®-baseddataacquisition. Used with the Magtrol DSP6001 Controller,MagtrolM-TEST5.0SoftwareprovidesthecontrolofanyMagtrolDynamometerandrunstestsequencesinamannerbestsuitedtotheoverallaccuracyandefficiencyoftheMagtrolMotorTestSystem.ThedatathatisgeneratedbyMagtrol’sMotorTestingSoftwarecanbestored,displayedandprintedintabularorgraphicformats,andcanbeeasilyimportedintoaspreadsheet.

Written inLabVIEW™,M-TEST5.0has theflexibility totestamajorityofmotortypesinavarietyofways.BecauseofLabVIEW’sversatility,obtainingdatafromothersources(e.g.thermocouples),controllingmotorpowerandprovidingaudio/visualindicatorsisrelativelyeasy.

Magtrol’sM-TEST5.0Softwareisidealforsimulatingloads,cyclingtheunitundertestandmotorramping.Becauseitiseasytogatherdataandduplicatetests,thesoftwareisidealforuseinengineeringlabs,productiontestingandincoming/outgoinginspection.

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Magtrol Model DSP6001 Dynamometer Controller Chapter 1 – Introduction

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DSP6001

MAGTROL

Specifications

FRONT PANEL

REAR PANEL

Set Desired Power Units(W, kW or Hp)

Set Desired Torque Units(oz.in., oz.ft., lb.in., lb.ft., g.cm, kg.cm, Nmm, Ncm, Nm)

Ready for Rack MountingDisplays Torque, Speed, Power,

Auxiliary and PID Values

Adjustable PID (Proportional Gain,Integral and Derivative) settingsprovide the best system response

Speed Control(up to 99,000 rpm)

RS-232 and GPIB/IEEE-488Interfaces for Connection to PC

For use with any Magtrol Dynamometer(Hysteresis, Eddy-Current, Powder Brake),

Magtrol Torque Transducer or auxiliary instrumentation

Connectors for ModelsDES310/DES311 Power Supplies(for WB/PB Dynamometers only)

Connector for Model 5241 Power Supply(for HD-825 Dynamometer only)

Torque/Speed Analog Output for Interfacing withData Acquisiton System or Strip Chart Recorder

MEASUREMENT CHARACTERISTICSMaximum Torque 10,000 units, ±5 V TSC1, ±10 V TSC2Maximum Speed 99,999 rpm

AccuracySpeed: 0.01% of reading from 10 rpm to 100,000 rpmTSC1: 0.02% of range (±1 mV)TSC2: 0.02% of range (±2 mV)

ELECTRICAL CHARACTERISTICS

Fuses (5 × 20 mm)

Brake: UL/CSA 1.25 A 250 V SB IEC 1.00 A 250 V TPower (120 V): UL/CSA 800 mA 250 V SBPower (240 V): IEC 315 mA 250 V T

Power Requirements 75 VAVoltage Requirements 120/240 V 60/50 HzMax. Compliance Voltage 45 V DC, Brake OutputINPUTS AND OUTPUTS

Maximum Torque Input TSC1: ±5 V DC TSC2: ±10 V DC

Accessory Torque/Speed Output

Torque: ±10 V DCSpeed: ±10 V DC

Ctrl Out 0–3 V DCENVIRONMENTOperating Temperature 5 ºC to 40 ºCRelative Humidity < 80%Temperature Coefficient 0.004% of range/°C of 5 V DC for both channels

DIMENSIONSWidth 19.0 in 483 mmHeight 3.5 in 89 mmDepth

with handles12.4 in13.8 in

315 mm351 mm

Weight 16.73 lb 7.58 kg

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DSP6001

MAGTROL

System Configurations

MotorUnderTest

OPTIONAL:

±10 voltsTSC2 only

14-pin connectorpin 13 = com

pin 14 = signal

Auxiliary Input

DYNAMOMETER / TSC1

AUX / TSC2

SUPPLY 2

SUPPLY 1 RS-232CGPIB/IEEE–488

BRAKE

ACCESSORYTORQUE–SPEED

OUTPUTCTRL OUT

BRAKE FUSE

CAUTION: DOUBLE POLE FUSING75VA 50/60Hz

EARTHGROUND

FUSE (5×20mm):120V UL/CSA 800mA 250V SB240V IEC 315mA 250V T

(5×20mm): UL/CSA 1.25A 250V SBIEC 1A 250V T MAGTROL, INC. BUFFALO, NY

No Connection

Hysteresis on TSC1 only

AC Mains

Hysteresis Dynamometer (HD)

DSP6001DYNAMOMETERCONTROLLER

GPIB

RS-232or

PC

M-TEST

– OR –

TM Torque Transducer

DYNAMOMETER / TSC1

AUX / TSC2

SUPPLY 2


BRAKE


OUTPUTCTRL OUT

BRAKE FUSE


EARTHGROUND



TM TorqueTransducer

GPIBor

RS-232

PC

M-TEST


Excitation

Torque

TSC 401Torque-SpeedConditioner

DES Power Supply

Speed

Eddy-Current (WB)OR Powder Brake (PB)Dynamometer

±10 voltsTSC2 only


pin 14 = signal

Auxiliary Input

– OR –

OPTIONAL:

DYNAMOMETER / TSC1

AUX / TSC2

SUPPLY 2


BRAKE


OUTPUTCTRL OUT

BRAKE FUSE


EARTHGROUND



No Connection


Eddy-Current (WB)OR Powder Brake (PB)

Dynamometer

AC Mains


Excitation

Torque

Speed


DES 31x Power Supply

MotorUnderTest

GPIB

RS-232or

PC

M-TEST


DSP6001 Connected to Hysteresis Dynamometer with Optional Auxiliary Input or In-Line Torque Transducer

DSP6001 Connected to Hysteresis Dynamometer and Eddy-Current or Powder Brake Dynamometer

DSP6001 Connected to Eddy-Current or Powder Brake Dynamometer (WB/PB)with Optional Auxiliary Input or In-Line Torque Transducer

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DSP6001

MAGTROL


DYNAMOMETER / TSC1

AUX / TSC2

SUPPLY 2


BRAKE


OUTPUTCTRL OUT

BRAKE FUSE


EARTHGROUND




Dynamometer

Excitation

Torque

Speed

TSC 401 Torque-SpeedConditioner



Excitation

Torque

Speed



DSP6001DYNAMOMETER CONTROLLER

GPIB

RS-232or

PC

M-TEST

DYNAMOMETER / TSC1

AUX / TSC2

SUPPLY 2


BRAKE


OUTPUTCTRL OUT

BRAKE FUSE


EARTHGROUND


(5×20mm): UL/CSA 1.25A 250V SBIEC 1A 250V T MAGTROL, INC. BUFFALO, NY GPIB

orRS-232

PC

M-TEST

Clutch(EK)

DSP6001Dynamometer

Controller

Transformer

Powder BrakeDynamometer (PB)

Excitation

Torque

DES Power Supply

TSC 401Torque/SpeedConditioner

Eddy-Current BrakeDynamometer (WB)

Excitation

Torque


DES Power Supply

Speed

DYNAMOMETER / TSC1

AUX / TSC2

SUPPLY 2


BRAKE


OUTPUTCTRL OUT

BRAKE FUSE


EARTHGROUND



Powder Brake (PB)Dynamometer

Eddy-Current (WB)Dynamometer

Excitation

Torque

Speed

TSC 401Torque-Speed Conditioner




Excitation

Torque

Speed



GPIB

RS-232or

PC

M-TEST

OR


DSP6001 Connected to 2 Eddy-Current or Powder Brake Dynamometers (Independent Setup)

DSP6001 Connected to 2 Eddy-Current or 2 Powder Brake Dynamometers (Tandem Setup)

DSP6001 Connected to Eddy-Current and Powder Brake Dynamometer (Tandem Setup)

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DSP6001

MAGTROL

DYNAMOMETER / TSC1

AUX / TSC2

SUPPLY 2


BRAKE


OUTPUTCTRL OUT

BRAKE FUSE


EARTHGROUND



Torque Transducer(TM)

No Connection

DES 31x

HysteresisBrake

Eddy-Current/Powder Brake

ORDSP6001

DYNAMOMETERCONTROLLER

GPIB

RS-232

M-TEST

orPC

CUSTOM MOTOR TEST SYSTEMTheDSP6001canbeincorporatedintoaCustomizedMotorTestSystem.ThesePCbased,turn-keysystemsarecustomdesignedandbuilttomeetspecificuserrequirements.

In-Line Torque Transducer Cross Loop Function


heavy-duty equipment rack

M-TEST Motor Testing Software

WB Eddy-Current Dynamometer

DES Power Supply

TSC Torque Signal Conditioner

AMF Adjustable Motor Fixture

Dynamometer Table

HD Hysteresis Dynamometer


6530 Power Analyzer

keyboard drawer

side panel connectors allow for easy hook-up

space for rackmountedthird-party power supply and computer

LCD monitor

emergency stop button

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DSP6001

Due to the continual development of our products, we reserve the right to modify specifications without forewarning.

www.magtrol.com

MAGTROL INC70 Gardenville ParkwayBuffalo, New York 14224 USAPhone: +1 716 668 5555Fax: +1 716 668 8705E-mail: [email protected]

MAGTROL SARoute de Montena 771728 Rossens / Fribourg, SwitzerlandPhone: +41 (0)26 407 3000Fax: +41 (0)26 407 3001E-mail: [email protected]

Subsidiaries in:Great Britain

Germany • FranceChina • India

Worldwide Network of Sales Agents

Ordering Information

6001

-US

08/

10

SYSTEM OPTIONS AND ACCESSORIES

ORDERING INFORMATION

DSP6001 High-Speed Programmable Dynamometer Controller 120 VACDSP6001A High-Speed Programmable Dynamometer Controller 240 VAC

CATEGORY DESCRIPTION MODEL / PART #

TESTINGDEVICES

Hysteresis Dynamometers HD series

Eddy-Current Dynamometers WB series

Powder Brake Dynamometers PB series

In-Line Torque Transducers TM/TMHS/TMB series

POWER ANALYZERS

High-Speed Single-Phase Power Analyzer 6510e

High-Speed Three-Phase Power Analyzer 6530

SOFTWAREM-TEST 5.0 Motor Testing Software SW-M-TEST5.0-WE

Temperature Testing Hardware HW-TTEST

POWER SUPPLIES

Closed-Loop Speed Control/Power Supply 6100

Power Supply 5200

Current-Regulated Power Supply 5210

Power Amplifier (required for HD-825 Dynamometer only) 5241

Power Supply for WB & PB Dynamometers series 2.7 and 43 DES 310

Power Supply for WB & PB Dynamometer series 65, 115 and 15 DES 311

MISC. Torque/Speed Conditioner (required for connecting WB/PB Series Dynamometers to DSP6001) TSC 401

CARDS &CABLES

GPIB Interface Card (PCI) 73-M023

GPIB Cable, 1 meter 88M047

GPIB Cable, 2 meters 88M048

Torque Transducer Connector Cable ER 113/01

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2. Controls

2.1 FRONT PANEL

The front panel provides a power switch, nine control buttons, a Decrease/Increase Dial, and Vacuum Fluorescent Display (VFD).


POWER

POWER


TORQUE SPEED STATUS

DECREASE INCREASE

UPDIP


SPEED SET

MAX SPEED

TORQUE SET

TORQUE UNITS

BRAKE ON/OFF

POWER UNITS

DOWN

Figure 2–1 Front Panel

2.2 FRONT PANEL CONTROLS AND BUTTONS

The front panel controls and buttons, from left to right, are:

• Powerswitch

• Sixdouble-functioncontrolbutton:

Primary Function Secondary FunctionBRAKE ON/OFF POWER UNITSTORQUE SET TORQUE UNITSSPEED SET MAX SPEEDP AUX SETUPI COM SETUPD DYNO SETUP

• Threesingle-functioncontrolbuttons:

• SHIFT(enablessavingfunctionandsecondaryfunctionsprintedinblueabovecontrolbuttons)

• UP-Leftarrow (moves cursor to the left)

• DOWN-Rightarrow (moves cursor to the right)

• Decrease/IncreaseDial(decreasesorincreasestheselectedparameter)

2.2.1 Enabling SEcondary FunctionS

To enable the secondary function of the double-function control buttons:

1. Press the blue SHIFT button and release it. The word “SHIFT” appears in the display:

POWER


TORQUE SPEED STATUS

Figure 2–2 Secondary Function Menu

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Magtrol Model DSP6001 Dynamometer Controller Chapter 2 – Controls

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2. Press any control button to enable the function shown in blue letters above the button.

3. Press the SHIFT button again to exit the secondary function and return to main menu.

Note: If the brake status is ON, the SHIFT button will be ignored.

2.2.2 Enabling Saving Function

To save all current programmed settings:

1. Press the SHIFT button two times. The word “SAVING” will appear in the display, as shown in Figure 2–3 Saving Function Menu.

POWER


TORQUE SPEED STATUS

Figure 2–3 Saving Function Menu

2. After a few seconds, the menu will automatically return to the main menu display and all configurations of the unit will be saved into a non-volatile memory.

2.2.3 How to uSE Front PanEl controlS and buttonS

2.2.3.1 Controls/Single-Function Buttons

Button To Use FunctionPOWER Press I to turn power ON Press O

to turn power OFF.Turns power ON or OFF.

SHIFT Press this button and release; then press desired control button.

Enables the function written in blue above control button.

Press this button two times and release.

Saves current configuration of unit to non-volatile memory.

UP/LEFT Press. Increases magnitude of change when adjusting a numerical value (speed, torque or max. speed).

DOWN/RIGHT Press. Decreases magnitude of change when adjusting a numerical value (speed, torque or max. speed).

DECREASE /INCREASE DIAL

Turn clockwise or counterclockwise.

Increases or decreases the parameter selected.

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2.2.3.2 Double-Function Buttons

Button To Use FunctionPOWER UNITS Press SHIFT and release; then

press this button.Sets desired unit of power. Press UP or DOWN button to see options. Press SHIFT to enable option.

BRAKE ON/OFF Press this button. Turns brake ON or OFF.TORQUE UNITS Press SHIFT and release; then

press this button.Sets desired unit of measure. Press UP or DOWN button to see options. Press SHIFT to enable option.

TORQUE SET Press this button. Enables adjustment of set point for torque loading.

Press and hold this button until second beep.

Enables Open Loop mode (if brake is off).

MAX SPEED Press SHIFT and release; then press this button.

Sets the speed range of the Controller.

SPEED SET Press this button. Enables adjustment of set point for speed loading.

AUX SETUP Press SHIFT and release; then press this button.

Turns auxiliary/torque transducer display ON or OFF. Enables adjustment of scale factors for torque and speed DAC’S.

P Press this button. Enables adjustment of proportional term.

COM SETUP Press SHIFT and release; then press this button.

Adjusts GPIB primary address and RS-232 baud rate. Also adjusts display contrast.

I Press this button. Enables adjustment of integral term.

DYNO SETUP Press SHIFT and release; then press this button.

Provides options to set maximum power, dynamometer settings (input units, maximum torque and scale factor), speed encoders and alarms.

D Press this button. Enables adjustment of derivative term.

2.3 VACUUM FLUORESCENT DISPLAY (VFD)

The VFD provides information about the control functions, the motor under test, and an auxiliary input device or In-Line Torque Transducer (if connected). The displays, from left to right, are:

Top Row Bottom RowPOWER BRAKE STATUS (ON or OFF)TORQUE SET POINT (TORQUE)SPEED SET POINT (SPEED)

AUX INPUT, TM2XX or STATUS DISPLAY

PID

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2.3.1 contraSt SEttingS

The DSP6001 is shipped with the Contrast Setting at zero (lowest) in order to prolong display life. If it is necessary to increase the Contrast for improved readability, execute the following steps:

1. Press SHIFT.

2. Press COM SETUP button.

3. Select CONTRAST until desired brightness is reached.

4. Press SHIFT to return to main menu.

Note: Make sure the lowest possible setting is used to achieve desired result. Using a setting higher than necessary may cause display segments to burn-in over a period of time, resulting in uneven illumination from segment to segment.

2.3.2 ScrEEn SavEr

In order to help eliminate the possibility of display damage, a Screen Saver has been programmed into the DSP6001. If the display has been turned on for more than 5 minutes without any activity, a Screen Saver with moving arrows will appear.

The display can be reactivated by any one of the following actions:

1. Touch any button on the Front Display Panel.

2. Send a command through the GPIB interface.

3. RPM activity in the motor under test.

Note: This function was removed after code revision 7.2.

2.3.3 StatuS diSPlay MESSagES

Message MeaningSHIFT Shift button was pressed.AUX Auxiliary unit is attached and enabled.Nm Torque Transducer attached and enabled.MAX SPEED Maximum motor RPM.I/O ERROR Incorrect command was sent from computer.UNITS Torque unit of measurement.REMOTE Remote control via PC enabled.RAMP DOWN Decrease motor speed by increasing load on motor.RAMP UP Increase motor speed by decreasing load on motor.SAVING Saves current configuration of unit to non-volatlie memory.

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2.4 REAR PANEL

The rear panel provides connectors and receptacles for connecting to appropriate equipment.

DYNAMOMETER / TSC1

AUX / TSC2

SUPPLY 2


BRAKE


OUTPUTCTRL OUT

BRAKE FUSE


EARTHGROUND



Figure 2–4 Rear Panel

2.5 REAR PANEL INPUTS AND OUTPUTS

BRAKE Connect dynamometer brake cable here.

(FUSED)+35V

REGULATIONCURRENT

Figure 2–5 Dynamometer Brake Input

BRAKEFUSE

Contains brake fuse (5 x 20 mm)(UL/CSA 1.25A 250V SB)(IEC 1A 250V T)

CTRL OUT Connect to Model 5241 Power Amplifier when using HD-825 Dynamometer.

ACCESSORYTORQUE/SPEEDOUTPUT

Connect accessory output cable here (optional).

7 6

3 1

5 42

8

8. +5.0 VDC COM7. EXTERNAL ALARM INPUT6. ALARM RELAY (COMMON)5. ALARM RELAY (NORMALLY CLOSED)4. ALARM RELAY (NORMALLY OPEN)3. ANALOG GROUND2. ANALOG SPEED1. ANALOG TORQUE

Figure 2–6 Accessory Torque-Speed Output

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DYNAMOMETER/TSC1

Connect dynamometer signal cable here.

14. TORQUE SIGNAL13. TORQUE COMMON12. D.P. B11. INDEX10. TACH. A 9. D.P. A 8. +5.0 VDC COM

7. +5.0 VDC 6. -24 VDC 5. -24 VDC COM 4. +24 VDC COM 3. +24 VDC 2. TACH. B 1. FLOW/CLUTCH

14 3 2

891011

6 5

1213

7

14

Figure 2–7 Dynamometer/TSC1 Connector

AUX/TSC2 Connect signal cables for the dynamometer, TM2XX or auxiliary instrument here.

11. N/C10. TACH. C 9. ROT_SENS 8. +5.0 VDC COM

14. TORQUE SIGNAL13. TORQUE COMMON12. BITE

6. -24 VDC

3. +24 VDC 2. N/C

5. -24 VDC COM 4. +24 VDC COM

1. SPARE

7. +5.0 VDC

14 3 2

891011

6 5

1213

7

14

Figure 2–8 AUX/TSC2 Connector

SUPPLY 1 Connect WB/PB DES supply for TSC1.

15. N/C14. CURRENT SET POINT (ANALOG 0V)13. +5.0 VDC COM12. SUPPLY +24 VDC11. STAND-BY CHANNEL 110. TEMPERATURE ALARM CHANNEL 1 9. SHIELD (EARTH) 8. W FLOW_1 7. CURRENT SET POINT (SIGNAL) 6. +5.0 VDC COM 5. SUPPLY +24 VDC 4. PRIMARY SUPPLY CONTR. CHANNEL 1 3. N/C 2. ELECTRICAL ALARM CHANNEL 1 1. SHIELD (EARTH)

14 3 25

912 11 10

68 7

14 1315

Figure 2–9 Supply 1 Connector

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SUPPLY 2 Connect WB/PB DES supply for TSC2.

3. CLUTCH

8. W FLOW_2

11. STAND-BY CHANNEL 2

1. SHIELD (EARTH) 2. ELECTRICAL ALARM CHANNEL 2

4. PRIMARY SUPPLY CONTR. CHANNEL 2 5. SUPPLY +24 VDC 6. +5.0 VDC COM 7. CURRENT SET POINT (SIGNAL)

9. SHIELD (EARTH)10. TEMPERATURE ALARM CHANNEL 2

15. N/C

13. +5.0 VDC COM14. CURRENT SET POINT (ANALOG 0V)

12. SUPPLY +24 VDC

14 3 25

912 11 10

68 7

14 1315


RS-232C Use this socket for RS-232 connector cable

5. GND

1.

6.

9. N/C

3. RX

8.

2. TX

4.

7.

14 3 25

69 8 7

Figure 2–11 RS-232C Interface

GPIB/IEEE-488 Use this socket for GPIB cable (meets IEEE-488 specifications).

24. SIGNAL GROUND23. ATN-COM22. SRQ-COM21. IFC-COM20. NDAC-COM19. NRFD-COM18. DAV-COM17. REN16. D815. D714. D613. D5

12. SHIELD11. ATN10. SRQ 9. IFC 8. NDAC 7. NRFD 6. DAV 5. E01 4. D4 3. D3 2. D2 1. D1

14 3 2

13141516

6 5

1718

7

19

811 10 9

20212223

12

24

Figure 2–12 GPIB/IEEE-488 Interface

POWER Attach power cord here.

EARTH GROUND Attach earth ground here.

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3. Installation/Configuration

Note: Before installing the DSP6001, you should become familiar with the front and rear panels, as outlined in Chapter 2–Controls.

3.1 POWERING UP THE DSP6001

WARNING! TO REDUCE THE RISK OF ELECTRIC SHOCK, MAKE SURE THE DSP6001 IS EARTH GROUNDED BEFORE STARTING!

3.1.1 Setting Unit for Line VoLtage

The DSP6001 will operate with either of the following power sources:

• 120V50/60Hz

• 240V50/60Hz

1. Find the line cord receptacle on rear panel. The line cord is a detachable NEMA Standard 3 wire.

2. Make sure the selector matches the power source (numbers should match the line voltage).

If not:

• Locatethepowerentrymodule.

• Removethelinecord.

• Insertascrewdriverintotheslotandopenthecover.

• Slidethevoltageselectorsothedesiredlinevoltageappearsinthewindow.

• Installtheappropriatefusesforthatvoltage.

Figure 3–1 Cover for Voltage Selector, Fuses

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3.1.2 SeLf-teSt

After turning the power on to the DSP6001, the display panel will show all segments of the VFD (series of rectangles), indicating that the DSP6001 is downloading the program.

POWER


TORQUE SPEED STATUS

Figure 3–2 Program Download Display

When the program download is complete, the message “MAGTROL MODEL DSP6001 Revision X.X” appears.

POWER


TORQUE SPEED STATUS

Figure 3–3 Revision Display

If the alarms are disabled, the following display message will appear at this time.

POWER


TORQUE SPEED STATUS

Figure 3–4 Alarm Warning Display

To activate the alarms, refer to Section 6.1.2.1 – How to Enable/Disable Alarms.

3.1.3 Main MenU

When the DSP6001 is completely powered up and ready for use, the main menu will appear on the display.

POWER


TORQUE SPEED STATUS

Figure 3–5 Main Menu

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3.2 TESTING INSTRUMENTATION SETUP

The DSP6001 has the ability to support a combination of up to two testing instruments with independent or tandem configurations. Typically used combinations include:

TSC1 TSC2 HD = Hysteresis DynamometerHD --- WB = Eddy-Current DynamometerHD TM2XX PB = Powder Brake DynamometerHD AUX TM2XX = In-Line Torque TransducerHD WB or PB AUX = Auxiliary Instrumentation

WB or PB --- BRAKE = Hysteresis, Eddy-Current or Powder Brake

WB or PB TM2XX --- = no connectionWB or PB AUXWB or PB WB or PBBRAKE TM2XX

Notes:

1. Only one Hysteresis Dynamometer, In-Line Torque Transducer or Auxiliary Instrument can be attached to the unit at any one time.

2. In the TSC1 (WB/PB) and TSC2 (WB/PB) combination, the instruments can be configured independently or as a tandem unit.

3. When there is no connection on TSC1 and TM2XX is connected to TSC2, the TM2XX will control the outputs of TSC1.

The setup of your unit will depend on which option you choose. The following sections will illustrate and outline the hardware connection and software configurations needed to begin your testing, based on your selection. For additional reference, see Appendix C: Front Panel/Display Menu Flow Charts.

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3.2.1 DynaMoMeter ConfigUration MenU

To reach the dynamometer configuration menu:

1. Turn on DSP6001 power. See Section 3.1 – Powering Up the DSP6001.

2. Press SHIFT. The word “SHIFT” will appear in the display.

3. Press the DYNO SETUP button. The display should appear as follows:

POWER


TORQUE SPEED STATUS

↓ ↓ ↓ ↓

Figure 3–6 Dyno Setup Menu

4. Select DYNAMOMETER. The display should appear as follows:

POWER


TORQUE SPEED STATUS

Figure 3–7 Dynamometer Configuration Menu

5. Pressing the POWER UNITS button allows selection of the preferred testing device (HD, WB, PB or BRAKE) for TSC1. Pressing the MAX SPEED button allows selection of the preferred testing device (AUX, WB, PB or TM2XX) for TSC2. Refer to the remainder of this chapter for more detailed instructions on setup and configuration of the different testing devices.

Note: For information on Filters, see Chapter 4 – Digital Filters.

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3.2.2 HyStereSiS DynaMoMeter SetUp

3.2.2.1 Hardware Connection

DYNAMOMETER / TSC1

AUX / TSC2

SUPPLY 2

SUPPLY 1 RS-232C GPIB/IEEE–488

BRAKE

ACCESSORY TORQUE–SPEED

OUTPUT CTRL OUT

BRAKE FUSE

CAUTION: DOUBLE POLE FUSING 75VA 50/60Hz

EARTH GROUND

FUSE (5×20mm): 120V UL/CSA 800mA 250V SB 240V IEC 315mA 250V T

(5×20mm): UL/CSA 1.25A 250V SB IEC 1A 250V T MAGTROL, INC. BUFFALO, NY

No Connection


AC Mains

Motor Under Test


DSP6001 DYNAMOMETER CONTROLLER

GPIB

RS-232 or

PC

M-TEST

Figure 3–8 Hysteresis Dynamometer Setup

3.2.2.2 Software Configuration1. Turn on the DSP6001 and proceed to the dynamometer configuration menu. See Section

3.2.1 – Dynamometer Configuration Menu.

2. Select TSC1 until HD is reached.

3. Select TSC2 until AUX is reached.

4. Press SHIFT. The display should appear as follows:

POWER


TORQUE SPEED STATUS

Figure 3–9 Hysteresis Setup Menu

5. Press the TORQUE UNITS button until the desired input unit for TSC1 is reached.

6. Press SHIFT 3 times to complete the initial setup and return to the main menu.

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3.2.3 HyStereSiS DynaMoMeter witH torqUe tranSDUCer SetUp


MotorUnderTest

DYNAMOMETER / TSC1

AUX / TSC2

SUPPLY 2


BRAKE


OUTPUTCTRL OUT

BRAKE FUSE


EARTHGROUND



TM Torque Transducer

AC Mains


No Connection



GPIB

RS-232or

PC

M-TEST

Figure 3–10 Hysteresis Dynamometer with Torque Transducer Setup

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3. Select TSC2 until TM2XX is reached.

4. Press SHIFT to get to the hysteresis setup menu. See Figure 3–9 Hysteresis Setup Menu.

5. Press TORQUE UNITS button until the desired input unit for TSC1 is reached.


POWER


TORQUE SPEED STATUS

Figure 3–11 Torque Transducer Setup Menu

7. Press TORQUE UNITS button and use UP and DOWN buttons and Decrease/Increase dial to set desired scale factor for TSC2.

8. Press SHIFT 3 times to return to the main menu.

9. To display the TSC2 torque transducer information in the main menu STATUS area, press SHIFT, AUX SETUP and the POWER UNITS button until the display says ON (as shown in Figure 3–12 Aux Setup Menu - Display On).

POWER


TORQUE SPEED STATUS

Figure 3–12 Aux Setup Menu - Display On

10. Press SHIFT to complete the initial setup and return to the new main menu. The display should appear as follows:

POWER


TORQUE SPEED STATUS

Figure 3–13 TSC1 with TM2XX Output Menu

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3.2.4 HyStereSiS DynaMoMeter witH aUxiLiary inStrUMentation SetUp


MotorUnderTest

DYNAMOMETER / TSC1

AUX / TSC2

SUPPLY 2


BRAKE


OUTPUTCTRL OUT

BRAKE FUSE


EARTHGROUND



No Connection


±10 voltsTSC2 only


pin 14 = signalAC Mains



Auxiliary Input (optional)

GPIB

RS-232or

PC

M-TEST

Figure 3–14 Hysteresis Dynamometer with Auxiliary Instrumentation Setup

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POWER


TORQUE SPEED STATUS

Figure 3–15 TSC2 Aux Setup Menu



9. To display the TSC2 auxiliary information in the main menu STATUS area, press SHIFT, AUX SETUP and the POWER UNITS button until the display says ON. See Figure 3–12 Aux Setup Menu - Display On.

10. Press SHIFT to complete the initial setup and return to the new main menu. The display should appear as follows:

POWER


TORQUE SPEED STATUS

Figure 3–16 TSC1 with AUX Output Menu

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3.2.5 HyStereSiS DynaMoMeter witH eDDy-CUrrent or powDer Brake SetUp


DYNAMOMETER / TSC1

AUX / TSC2

SUPPLY 2


BRAKE


OUTPUTCTRL OUT

BRAKE FUSE


EARTHGROUND



No Connection



Dynamometer

AC Mains


Excitation

Torque

Speed



MotorUnderTest

GPIB

RS-232or

PC

M-TEST


Figure 3–17 Hysteresis Dynamometer with Eddy-Current or Powder Brake Setup

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3. Select TSC2 until WB or PB is reached.




POWER


TORQUE SPEED STATUS

Figure 3–18 TSC2 Eddy-Current/Powder Brake Setup Menu


8.a. If using an Eddy Current Dynamometer, press SHIFT 2 times. The display should appear as follows:

POWER


TORQUE SPEED STATUS

Figure 3–19 Nominal Speed Setup Menu

Press the AUX SETUP button and use UP and DOWN buttons and Decrease/Increase dial to set desired nominal speed. Press SHIFT 3 times to complete the initial setup and return to the main menu.

8.b. If using a Powder Brake Dynamometer, press SHIFT 3 times to complete the initial setup and return to the main menu.

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3.2.6 eDDy-CUrrent or powDer Brake DynaMoMeter SetUp


DYNAMOMETER / TSC1

AUX / TSC2

SUPPLY 2


BRAKE


OUTPUTCTRL OUT

BRAKE FUSE


EARTHGROUND



orRS-232

PC

M-TEST

Excitation

Torque


DES Power Supply

Speed



Figure 3–20 Eddy-Current or Powder Brake Dynamometer Setup






POWER


TORQUE SPEED STATUS

Figure 3–21 TSC1 Eddy-Current/Powder Brake Setup Menu

5. Press TORQUE UNITS button and use UP and DOWN buttons and Decrease/Increase dial to set desired scale factor.

6.a. If using an Eddy Current Dynamometer, press SHIFT 2 times. The display should appear as shown in Figure 3–19 Nominal Speed Setup Menu. Press the AUX SETUP button and use UP and DOWN buttons and Decrease/Increase dial to set desired nominal speed. Press SHIFT 4 times to complete the initial setup and return to the main menu.

6.b. If using a Powder Brake Dynamometer, press SHIFT 4 times to complete the initial setup and return to the main menu.

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3.2.7 eDDy-CUrrent or powDer Brake DynaMoMeter witH torqUe tranSDUCer SetUp


DYNAMOMETER / TSC1

AUX / TSC2

SUPPLY 2


BRAKE


OUTPUTCTRL OUT

BRAKE FUSE


EARTHGROUND



TM TorqueTransducer

GPIBor

RS-232

PC

M-TEST


Excitation

Torque


DES Power Supply

Speed


Figure 3–22 Eddy-Current or Powder Brake Dynamometer with Torque Transducer Setup





4. Press SHIFT to get to the TSC1 eddy-current/powder brake setup menu. See Figure 3–21 TSC1 Eddy-Current/Powder Brake Setup Menu.


6.a. If using an Eddy Current Dynamometer, press SHIFT 2 times. The display should appear as shown in Figure 3–19 Nominal Speed Setup Menu. Press the AUX SETUP button and use UP and DOWN buttons and Decrease/Increase dial to set desired nominal speed. Press SHIFT 2 times to get to the Torque Transducer Setup Menu as shown in Figure 3-11.

6.b. If using a Powder Brake Dynamometer, press SHIFT 2 times to get to the Torque Transducer Setup Menu as shown in Figure 3–11.



9. To display the TSC2 torque transducer information in the main menu STATUS area, press SHIFT, AUX SETUP and the POWER UNITS button until the display says ON. See Figure 3–12 Aux Setup Menu - Display On.

10. Press SHIFT to complete the initial setup and return to the new main menu. See Figure 3–13 TSCI with TM2XX Output Menu.

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3.2.8 eDDy-CUrrent or powDer Brake DynaMoMeter witH aUxiLiary inStrUMentation SetUp


DYNAMOMETER / TSC1

AUX / TSC2

SUPPLY 2


BRAKE


OUTPUTCTRL OUT

BRAKE FUSE


EARTHGROUND



orRS-232

PC

M-TEST


Excitation

Torque


DES Power Supply

Speed


±10 voltsTSC2 only


pin 14 = signal

Auxiliary InputOPTIONAL:

Figure 3–23 Eddy-Current or Powder Brake Dynamometer with Auxiliary Instrumentation Setup







6.a. If using an Eddy Current Dynamometer, press SHIFT 2 times. The display should appear as shown in Figure 3–19 Nominal Speed Setup Menu. Press the AUX SETUP button and use UP and DOWN buttons and Decrease/Increase dial to set desired nominal speed. Press SHIFT 2 times to get to the Auxiliary Instrumentation Setup Menu as shown in Figure 3–15.

6.b. If using a Powder Brake Dynamometer, press SHIFT 2 times to get to the Auxiliary Instrumentation Setup Menu as shown in Figure 3-15.



9. To display the TSC2 auxiliary information in the main menu STATUS area, press SHIFT, AUX SETUP and the POWER UNITS button until the display says ON. See Figure 3–13 Aux Setup Menu - Display On.

10. Press SHIFT to complete the initial setup and return to the new main menu. See Figure 3–16 TSC1 with AUX Output Menu.

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3.2.9 two eDDy-CUrrent/powDer Brake DynaMoMeterS (inDepenDent SetUp)


DYNAMOMETER / TSC1

AUX / TSC2

SUPPLY 2


BRAKE


OUTPUTCTRL OUT

BRAKE FUSE


EARTHGROUND




Dynamometer

Excitation

Torque

Speed




Excitation

Torque

Speed




GPIB

RS-232or

PC

M-TEST

Figure 3–24 Two Eddy-Current/Powder Brake Dynamometers (Independent Setup)

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6.a. If using an Eddy Current Dynamometer, press SHIFT 2 times. The display should appear as shown in Figure 3 –19 Nominal Speed Setup Menu. Press the AUX SETUP button and use UP and DOWN buttons and Decrease/Increase dial to set desired nominal speed. Press SHIFT 2 times to get to the TSC2 Eddy-Current/Powder Brake Setup Menu as shown in Figure 3–18.

6.b. If using a Powder Brake Dynamometer, press SHIFT 2 times to get to the TSC2 Eddy-Current/Powder Brake Setup Menu as shown in Figure 3–18.


8.a. If using an Eddy Current Dynamometer, press SHIFT 2 times. The display should appear as shown in Figure 3–19 Nominal Speed Setup Menu. Press the AUX SETUP button and use UP and DOWN buttons and Decrease/Increase dial to set desired nominal speed. Press SHIFT 2 times.

8.b. If using a Powder Brake Dynamometer, Press SHIFT 2 times.

9. The menu will appear as follows:

POWER


TORQUE SPEED STATUS

Figure 3–25 Tandem Configuration Menu

10. Press the COM SETUP button until the menu says “NO”.


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3.2.10 two eDDy-CUrrent/powDer Brake DynaMoMeterS (tanDeM SetUp)


DYNAMOMETER / TSC1

AUX / TSC2

SUPPLY 2


BRAKE


OUTPUTCTRL OUT

BRAKE FUSE


EARTHGROUND





Excitation

Torque

Speed





Excitation

Torque

Speed



GPIB

RS-232or

PC

M-TEST

OR


Figure 3–26 Two Eddy-Current/Powder Brake Dynamometers (Tandem Setup)

Note: This particular tandem configuration is only applicable to a WB-WB or PB-PB combination.

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6.a. If using an Eddy Current Dynamometer, press SHIFT 2 times. The display should appear as shown in Figure 3 –19 Nominal Speed Setup Menu. Press the AUX SETUP button and use UP and DOWN buttons and Decrease/Increase dial to set desired nominal speed.Press SHIFT 2 times to get to the TSC2 Eddy-Current/Powder Brake Setup Menu as shown in Figure 3–18.

6.b. If using a Powder Brake Dynamometer, press SHIFT 2 times to get to the TSC2 Eddy-Current/Powder Brake Setup Menu as shown in Figure 3–18.


8.a. If using an Eddy Current Dynamometer, press SHIFT 2 times. The display should appear as shown in Figure 3–19 Nominal Speed Setup Menu. Press the AUX SETUP button and use UP and DOWN buttons and Decrease/Increase dial to set desired nominal speed. Press SHIFT 2 times.

8.b. If using a Powder Brake Dynamometer, Press SHIFT 2 times.

9. The Tandem Configuration Menu will appear as shown in Figure 3–25.

10. Press the COM SETUP button until the menu says “YES”.


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3.2.11 eDDy-CUrrent DynaMoMeter witH powDer Brake DynaMoMeter (tanDeM SetUp)


DYNAMOMETER / TSC1

AUX / TSC2

SUPPLY 2


BRAKE


OUTPUTCTRL OUT

BRAKE FUSE


EARTHGROUND



orRS-232

PC

M-TEST

Clutch(EK)

DSP6001Dynamometer

Controller

Transformer

Powder BrakeDynamometer (PB)

Excitation

Torque

DES Power Supply

TSC 401Torque/SpeedConditioner

Eddy-Current BrakeDynamometer (WB)

Excitation

Torque


DES Power Supply

Speed

Figure 3–27 Eddy-Current Dynamometer with Powder Brake Dynamometer (Tandem Setup)



2. Select TSC1 until WB is reached.

3. Select TSC2 until PB is reached.

4. Press SHIFT to get to the TSC1 Eddy-Current Setup Menu as seen below.

POWER


TORQUE SPEED STATUS

Figure 3–28 TSC1 Eddy-Current Setup Menu


6. Press SHIFT 2 times. The display should appear as shown in Figure 3–19 Nominal Speed Setup Menu.

7. Press the AUX SETUP button and use UP and DOWN buttons and Decrease/Increase dial to set desired nominal speed.

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8. Press SHIFT 2 times to get to the TSC2 Powder Brake Setup Menu as shown below.

POWER


TORQUE SPEED STATUS

Figure 3–29 TSC2 Powder Brake Setup Menu


10. Press SHIFT 2 times. The menu will appear as shown in Figure 3–25 Tandem Configuration Menu.

11. Press the COM SETUP button until the menu says “YES”.

12. Press SHIFT once to reach the Maximum Speed Excited Menu as shown below.

POWER


TORQUE SPEED STATUS

Figure 3–30 Maximum Speed Excited Menu

13. Press the AUX SETUP button and use UP and DOWN buttons and Decrease/Increase dial to set maximum speed excited of PB.

14. Press SHIFT 3 times to complete initial setup and return to the main menu.

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3.2.12 in-Line torqUe tranSDUCer CroSS Loop fUnCtion


DYNAMOMETER / TSC1

AUX / TSC2

SUPPLY 2


BRAKE


OUTPUTCTRL OUT

BRAKE FUSE


EARTHGROUND



Torque Transducer(TM)

No Connection

DES 31x

HysteresisBrake

Eddy-Current/Powder Brake

ORDSP6001

DYNAMOMETERCONTROLLER

GPIB

RS-232

M-TEST

orPC

Figure 3–31 In-Line Torque Transducer Cross Loop Function

Note: In the Torque Transducer Cross Loop Function, the TM2XX is connected to TSC2 while controlling the outputs of TSC1. The connection allows closed loop control of a brake via the Torque Transducer.



2. Select TSC1 until BRAKE is reached.


4. Press SHIFT to get to the Torque Transducer Setup Menu as shown in Figure 3-11.


6. Press SHIFT 2 times to reach the Brake Type menu as seen below.

POWER


TORQUE SPEED STATUS

Figure 3–32 Brake Type Menu

7. Press POWER UNITS button until desired Brake Type is reached.

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8.a. If choosing a Hysteresis or Powder Brake Type, press SHIFT 2 times to complete setup and return to main menu.

8.b. If choosing an Eddy-Current Brake Type, menu will appear as follows:

POWER


TORQUE SPEED STATUS

Figure 3–33 Brake Type Menu (for WB)

Press AUX SETUP button and use UP and DOWN buttons and Decrease/Increase dial to set nominal speed. Then press SHIFT 3 times to complete setup and return to main menu.

3.3 SPEED ENCODER SETUP

1. Starting from main menu, press SHIFT.

2. Press DYNO SETUP.

3. Select ENCODERS. The display should appear as follows:

POWER


TORQUE SPEED STATUS

Figure 3–34 Encoder Menu

4. Press TORQUE UNITS button until the desired bit selection for TSC1 is reached.

5. To set bits for TSC2, press POWER UNITS button once, then press TORQUE UNITS button until the desired bit selection is reached.

6. Press SHIFT 2 times to complete SPEED ENCODER setup and return to the main menu.

3.3.1 Bit ConfigUrationS

Standard bit configurations are as follows:

Test Instrument EncoderHysteresis Dynamometer 60 bit*Eddy-Current Dynamometer 20, 30 and 60 bit*Powder Brake Dynamometer 20, 30 and 60 bit*In-Line Torque Transducer 30 and 60 bit

* 600 and 6000 bit also available

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3.4 TORQUE/SPEED ANALOG OUTPUTS

Torque and Speed DAC Outputs provide an analog output proportional to the torque and speed of the system. They are available on the Accessory Torque-Speed Output Connector (as seen in Figure 2–6 Accessory Torque-Speed Output) and are updated every 2 milliseconds. Both of the outputs have a user definable Scale Factor found under the SHIFT/AUX SETUP key sequence.

3.4.1 torqUe DaC SCaLe faCtor

Torque DAC Scale Factor is scaled in displayed torque units/volt.

Example: If the displayed torque units are set to oz.in. and the Torque DAC scale is set to 1 unit/volt,

then 1 oz.in. will result in 1 volt at the torque output.

3.4.2 SpeeD DaC SCaLe faCtor

Speed DAC Scale Factor is scaled in rpm/volt.

Example: If the Speed DAC scale is set to 1000 rpm/volt, then 1000 rpm will result in 1 volt at the

speed output.

3.4.3 torqUe/SpeeD DaC SetUp


2. Press AUX SETUP. The display should appear as follows:

POWER


TORQUE SPEED STATUS

Figure 3–35 Torque/Speed DAC Setup Menu

3. Press TORQUE UNITS button and use UP and DOWN buttons and Decrease/Increase dial to set desired Torque DAC value.

4. Press SHIFT.

5. Press AUX SETUP button and use UP and DOWN buttons and Decrease/Increase dial to set desired Speed DAC value.

6. Press SHIFT two times to return to main menu.

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4. Digital Filters

The Digital Filters of the DSP6001 are used to remove undesired noise from the TSC inputs. This noise could be conducted from an undesired measured signal such as mechanical vibration or other electrical sources.

4.1 FILTER PARAMETERS

The input to the A/D converter internal to the DSP6001 has a traditional analog filter that is comprised of the following characteristics:

• -3dbPoint:3.8KHz

• A/DSampleRate:7812.5KHz

• 16AcquiredandAveragedSamples:Averageappliedtofilteratarateof488.28125Hz

• FilterCutoffFrequencies:3Hz,10Hz,25Hz,50Hz

• FilterOutput:EquivalenttosecondorderButterworthanalogfilter

• TransposedDirectFormIIArchitecture:Thediagrambelowshowsthisarchitecture.

Z-1

+

Z -1

+

-a0

b0

+b1

b2 -a1

x(n) y(n)

w1

w2

Transposed Direct Form IIFigure 4–1 Transposed Direct Form II Architecture

With a Digital Filter, the DSP6001 is able to solve the following equations:

y(n) = b0 * x(n) + w1

w1 = b1 * x(n) + a1 * y(n) + w2

w1 = b2 * x(n) + a2 * y(n)

The equations are applicable to each channel, occurring every 2.48 milliseconds.

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Magtrol Model DSP6001 Dynamometer Controller Chapter 4 – Digital Filters

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4.2 FILTER SETUP

Note: Filter setup should take place after hardware installation and software configuration of the chosen testing instruments has been completed. See Chapter 3 – Installation/Configuration.

There are four different Filter settings to choose from including 10 Hz, 25 Hz, 50 Hz and OFF. The following instructions show how to select the desired Filter for each channel:

1. Starting from the main menu, press SHIFT.

2. Press DYNO SETUP button.

3. Select DYNAMOMETER.

4. Press TORQUE UNITS button until the desired TSC1 Filter setting is reached.

5. Press COM SETUP button until the desired TSC2 Filter setting is reached.

6. Press SHIFT repeatedly until the main menu is reached. The number of times will vary depending on testing instrument selection.

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5. PID Settings

5.1 ABOUT THE PID LOOP

The DSP6001 has PID adjustment capability for both the speed and torque modes to provide the best system response. The PID Loop comprises the following three variables:

P = proportional gain

I = integral

D = derivative

Other important variables include:

• Setpoint-desiredloadorspeed

• Error-differencebetweenthesetpointandtheactualmeasurement

5.1.1 p (proportionaL gain)

With proportional gain, the controller output is proportional to the error or to a change in measurement. Deviation from the set point is usually present. Increasing the proportional gain will make the PID loop unstable. Increasing the integral value will eliminate this instability. For best loop control, set the proportional gain as high as possible without causing the loop to become unstable.

5.1.2 i (integraL)

With integral, the controller output is proportional to the amount of time the error is present. Increasing the integral value eliminates the offset from the set point. If the response becomes oscillatory increase the derivative value.

5.1.3 D (DeriVatiVe)

With derivative, the controller output is proportional to the rate of change of measurement or error. Derivative can compensate for a changing measurement. Derivative takes action to inhibit more rapid changes of the measurement than proportional gain.

5.2 SETTING PID VALUES

5.2.1 How to Set p (proportionaL gain) VaLUe

1. Starting at the main menu press the P button.

2. Use the Decrease/Increase dial until the desired percentage is reached (ranges from 0-99).

5.2.2 How to Set i (integraL) VaLUe

1. Starting at the main menu press the I button.


5.2.3 How to Set D (DeriVatiVe) VaLUe

1. Starting at the main menu press the D button.


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5.3 HOW THE PID LOOP WORKS

The following diagram demonstrates the correlation between the variables in the PID LoOp.

Derivative Proportional

Integral

Set Point

Reading

-

e(t) Yd(t) Yp(t)

Yi(t)

Yt(t)Ys(t)

+ +Scale

A/DPower

AmplifierBrakeCoil

TSC LoadCellAmplifier

Amplifier

TORQUE

SPEED

SpeedCorrection

Yswb(t)or

HD & PB

WB

IIR Filter

Figure 5–1 System Block Diagram

5.3.1 SCaLe faCtorS for HyStereSiS, eDDy-CUrrent anD powDer Brake DynaMoMeterS

Yt(t) Ys(t)Scale

TORQUE: TSC1 Ys(t) = Yt(t) / 1.725 * 2

TSC2 Ys(t) = Yt(t) / 1.725 * 2 * 1.6623

SPEED: TSC1 & TSC2 Ys(t) = Yt(t) * 5319.93 / MAX SPEED

5.3.2 SpeeD CorreCtion for wB (eDDy-CUrrent Brake) DynaMoMeter

Ys(t) Yswb(t)Speed Correction

The WB Dynamometer follows the same scaling as the HYST and PB with the addition of one calculation for both torque and speed. This calculation is due to the fact that for a given current the torque changes with speed. This is referred to as speed correction.

Yswb(t) = (Ys(t) + Ys(t) / speed correction factor) / 2

The speed correction factor is calculated on each entry into the PID loop equations.

Speed Correction Factor = - 0.0001 * x * 2 + 0.0203 * x + 0.005 limited to 0.051 to 1

where x = RPM / NOMINAL SPEED * 100

NOMINAL SPEED is set by the user and obtained from the data sheets for the dynamometer or brake.

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5.3.3 eqUationS

Where Skp, Ski and Skd are system coefficients…

Yd(t) = (e(t) - e(t-3) + 3 * (e(t-1) - e(t-2))) * (10/Skd) * D%

Yp(t) = (e(t) + Yd(t)) * (10/Skp) * P%

Yi(t) = Yi(t-1) + (e(t) + Yd(t)) * (10/Ski) * I%

Yt(t) = Yp(t) + Yi(t)

Ys(t) = Scale * Yt(t)

5.4 ADDITIONAL SCALE FACTOR

The Additional Scale Factor is a multiplier of the P, I or D term. Due to the fact there are so many different dynamometer types and motor combinations, this multiplier is needed to extend the range of the PID. The letters represent the following:

A = 0.001 F = 0.5

B = 0.005 G = 1

C = 0.01 H = 5

D = 0.05 I = 10

E = 0.1

In using the multiplier, the user can input PID numbers from 0.001 (.001 x 1%) to 990 (10.0 x 99%) with good resolution.

5.4.1 How to Set aDDitionaL SCaLe faCtor

Before following the setup instructions, the values that must be set will need to determined. This will depend on which testing instrument has been chosen for the configuration. For appropriate settings, refer to the guide provided in Appendix F: Additional Scale Factor Table. Once the proper settings have been determined, proceed with the following instructions for setup.

5.4.1.1 Setting Additional Scale Factor for P (Proportional Gain)1. Starting from the main menu, press and hold the P button. While holding the P button, press

SHIFT.

2. Use the P button to toggle through the letters in the unit (A, B, C, D, E, F, G, H and I).

3. Choose the letter that corresponds with the pre-determined setting provided in the Additional Scale Factor Table shown in Appendix F.

4. Once the letter is chosen, press SHIFT to return to the main menu.

5.4.1.2 Setting Additional Scale Factor for I (Integral)1. Starting from the main menu, press and hold the I button. While holding the I button, press

SHIFT.

2. Use the I button to toggle through the letters in the unit (A, B, C, D, E, F, G, H and I).



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5.4.1.3 Setting Additional Scale Factor for D (Derivative)1. Starting from the main menu, press and hold the D button. While holding the D button,

press SHIFT.

2. Use the D button to toggle through the letters in the unit (A, B, C, D, E, F, G, H and I).



5.5 SETTING THE CORRECT PID’S FOR YOUR MOTOR

Note: Each type of motor will have it’s own optimum PID setting at different load points.

5.5.1 Setting tHe piD witH an Unknown Motor or SySteM

If the user is unfamiliar with the characteristics of the motor under test, it is recommended to begin in Open Loop Control mode. In doing so, the user can safely get an idea of the motor’s performance.

1. To enter Open Loop Control mode, begin with the motor and brake OFF. Press and hold the TORQUE SET button until a second beep is heard. The display will appear as follows:

POWER


TORQUE SPEED STATUS

Figure 5–2 Open Loop Control Menu

2. Set the percent excitation to zero.

3. Start the motor.

4. Slowly increase the excitation current to the brake.

5. Make a note of the torque and speed values of which the motor is capable.

6. To exit the Open Loop Control mode and return to the main menu, turn the motor and brake OFF and press and hold the TORQUE SET button until a second beep is heard.

5.5.2 Setting tHe piD for torqUe ControL

1. With the motor and brake OFF, set the desired Torque Set Point by pressing the TORQUE SET button and using the UP and DOWN buttons and Decrease/Increase dial.

2. Set the P, I and D values to zero.

3. Turn the motor ON.

4. Turn the brake ON.

5. Slowly increase the P term until the torque read is about 25% of the desired load point.

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Figure 5–3 Initial P Setting for Torque Control at 25%

Figure 5–4 High Initial P Setting for Torque Control

6. Turn the brake OFF.

7. Increase the I term to 10%.

8. Turn the brake ON and observe response, then turn the brake OFF. Desired Result is a fast response with some over shoot.

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a. If the response was too slow, increase the I term in 1-5% increments and repeat #8.

b. If the response was too fast, decrease the I term in 1-5% increments and repeat #8.

Figure 5–5 Initial I Setting for Torque Control

c. If there is too much over shoot, increase the D term in 1% increments and repeat #8. For each incremental increase of the D term, reduce the P term by a proportional amount.

Figure 5–6 Initial D Setting for Torque Control

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5.5.3 Setting tHe piD for SpeeD ControL

1. With the motor and brake OFF, set the desired Speed Set Point by pressing the SPEED SET button and using the UP and DOWN buttons and Decrease/Increase dial.

2. Set the P, I and D values to zero.

3. Turn the motor ON.

4. Turn the brake ON.

5. Slowly increase the P term until the speed read is about 25% of the desired load point.

Figure 5–7 Initial P Setting for Speed Control at 25%

6. Turn the brake OFF.

7. Increase the I term to 10%.

8. Turn the brake ON and observe response, then turn the brake OFF. Desired Result is a fast response with some over shoot.

a. If the response was too slow, increase the I term in 1-5% increments and repeat #8.

b. If the response was too fast, decrease the I term in 1-5% incremets and repeat #8.

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Figure 5–8 Initial I Setting for Speed Control

c. If there is too much over shoot, increase the D term in 1% increments and repeat #8. For each incremental increase of the D term, reduce the P term by a proportional amount.

Figure 5–9 Initial D Setting for Speed Control

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5.5.4 Setting tHe piD for raMp Down

It is nearly impossible to select a PID value that optimizes the control loop over a wide range of speed. With Magtrol’s experience in motor test, their engineers have developed a dynamic PID algorithm. The PID values change with the Speed Set Point. In most cases, the PID values are high when the motor is lightly loaded and tend to decrease at higher loads.

Magtrol’s M-TEST Software provides a setup PID function in the setup for the ramp test. In the M-TEST Software, the dynamic scaling can be enabled or disabled and the span of the scaling can also be selected.

Figure 5–10 Ramp Down Low I

Ramp shows low value for I term. Note “bump” at beginning of ramp and good results toward end of ramp.

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Figure 5–11 Ramp Down High I

Ramp shows higher value for I term. Note “bump” at beginning of ramp has been reduced but there are poor results toward end of ramp.

Figure 5–12 Ramp Down Dynamic I

Ramp shows Dynamic Scale effect. Note “bump” at beginning of ramp has been reduced and there are good results toward end of ramp. DIL was set to .01. At the end of the ramp, the I term is 1/100th of the starting value.

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6. Alarm System

6.1 GENERAL INFORMATION

New to the DSP6001 is a built-in alarm system, designed to caution the user when problems occur. An automatic electrical and temperature alarm is programmed into the unit to protect against electrical overloads and overheating equipment when using a Magtrol DES 3XX Power Supply. There are also power, speed, torque, air flow, water flow and external input alarms internal to the unit, which only become active when enabled by the user. Instructions on how to set up and activate these alarms are included in this chapter.

6.1.1 aLarM reLay

Internal to the DSP6001 is a relay that operates in conjunction with the alarms.

Relay Specifications:

•ContactConfiguration:1FORMC

•ContactRating:1amp,24VDC

•ManufacturerP/N:OMRONG5V-2-H1-DC24

The relay has normally open and normally closed contacts. Under normal conditions, the relay is energized as shown in Figure 6–1.

COMMON

N.O.

N.C.

Normal Operation“CLOSED”

Figure 6–1 Normal Condition “Energized Relay”

In an alarm condition (or power failure), the relay is de-energized as shown in Figure 6–2.

COMMON

N.O.

N.C.

Alarm Condition“OPEN”

Figure 6–2 Alarm Condition “De-Energized Relay”

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The relay contacts are made accessible on the Accessory Torque/Speed Output rear panel connector. See Figure 2–6.

COMMON

N.O.

N.C.

24VDC

Contactor coil

AC Mains

MotorUnderTest

Figure 6–3 Typical Application

6.1.2 aLarM operation

The DSP6001 gives the user the ability to enable or disable the alarms in the unit. The default is set in the OFF position. In order for the alarms to be operative the user must enable them.

6.1.2.1 How to Enable/Disable Alarms1. Starting from main menu, press SHIFT.


3. Select ALARMS.

4. Press SHIFT 3 times. The display should appear as follows:

POWER


TORQUE SPEED STATUS

Figure 6–4 Alarm Enable/Disable Menu

5. Press COM SETUP button until you reach desired selection (YES or NO).


Note: Once the alarms are activated, they are only monitored for the channel that the control loop is closed on. For example, if the DSP6001 is controlling on TSC1, alarms for TSC2 are ignored.

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6.1.3 aLarM priority

While in an alarm condition, a higher priority alarm will be acknowledged, while lower priority alarms are ignored. The priority order is as follows.

Priority AlarmAvailability

Hysteresis Dynamometer

Eddy-Current/Powder Brake Dynamometer

1 Electrical Alarm N/A X2 Temperature Alarm N/A X3 External Alarm X X4 Air Flow Alarm X N/A5 Water Flow Alarm N/A X6 Maximum Torque X X7 Maximum Speed X X8 Power X X

6.2 POWER ALARM

• Usedtoindicateanoverpowercondition

• Defaultissetat1kW

6.2.1 inStrUCtionS for power aLarM SetUp



3. Select MAXPOWER. The display should appear as follows:

POWER


TORQUE SPEED STATUS

Figure 6–5 Max Power Menu

4. Press MAX SPEED button and use UP and DOWN buttons and Decrease/Increase dial to set desired maximum power value for TSC1.

5. Press SHIFT.

6. Press POWER UNITS button, then MAX SPEED button and use UP and DOWN buttons and Decrease/Increase dial to set desired maximum power value for TSC2.

7. Press SHIFT 3 times to complete Power Alarm setup and return to the main menu.

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6.2.2 power aLarM aCtion

When the power exceeds that of the maximum power setting, the message -OL- will appear and blink in the power section of the display accompanied by an audible beeping sound (as indicated in Figure 6–6).

POWER


TORQUE SPEED STATUS

Figure 6–6 Power Alarm Display

Because torque and speed have separate setable limits, no other action will be taken. If condition persists the temperature sensors will open causing the temperature alarm to activate.

6.2.3 to reSet power aLarM

This is a non-latching alarm. When the condition goes away, the alarm will automatically stop.

6.3 MAXIMUM SPEED ALARM

• Usedtolimitspeedofsystem(motor,dynamometer,couplings,etc.)

• Defaultissetat4000rpm

6.3.1 inStrUCtionS for MaxiMUM SpeeD aLarM SetUp



3. Select ENCODERS. The display should appear as follows:

POWER


TORQUE SPEED STATUS

Figure 6–7 Speed Alarm Setup Menu

4. Press MAX SPEED button and use UP and DOWN buttons and Decrease/Increase dial to set desired maximum speed for TSC1.

5. Press SHIFT.

6. Press POWER UNITS button, then MAX SPEED button and use UP and DOWN buttons and Decrease/Increase dial to set desired maximum speed for TSC2.

7. Press SHIFT 3 times to complete Maximum Speed Alarm setup and return to the main menu.

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6.3.2 MaxiMUM SpeeD aLarM aCtion

A. If speed is greater than the maximum speed setting but less than 120%, -OL- will flash on the display where the speed reading was (as indicated in Figure 6–8) and will be accompanied by an audible beeping sound.

POWER


TORQUE SPEED STATUS

Figure 6–8 -OL- Speed Alarm Display

B. If speed is greater than 120% of the maximum speed setting or in condition A for greater than 5 seconds, the display will flash “OVER SPEED ALARM TSCX” (as indicated in Figure 6–9) and will be accompanied by an audible beeping sound. The alarm relay will open, excitation current will hold at last value for 3 seconds then drop to zero.

POWER


TORQUE SPEED STATUS

∗∗∗∗ ∗∗∗∗

Figure 6–9 Over Speed Alarm Message Display

6.3.3 to reSet MaxiMUM SpeeD aLarM

Press any front panel button other than SHIFT. If the alarm condition is clear, the unit will return to normal operation. Although not recommended, another option would be to disable the alarm by following the alarm setup instructions in Section 6.3.1 – Instructions for Maximum Speed Alarm Setup.

6.4 MAXIMUM TORQUE ALARM

• Used to protect the system (motor, dynamometer, couplings, etc.) from over torquecondition

• Defaultissetat1inputunit

6.4.1 inStrUCtionS for MaxiMUM torqUe aLarM SetUp



3. Select DYNAMOMETER.


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POWER


TORQUE SPEED STATUS

Figure 6–10 Torque Alarm Setup Menu

5. Press AUX SETUP button and use UP and DOWN buttons and Decrease/Increase dial to set desired maximum torque for TSC1.

6. Press SHIFT until Torque Alarm Setup Menu for TSC2 is reached.

7. Press AUX SETUP button and use UP and DOWN buttons and Decrease/Increase dial to set desired maximum torque for TSC2.

8. To complete Maximum Torque alarm setup, continue pressing SHIFT until main menu is reached.

6.4.2 MaxiMUM torqUe aLarM aCtion

A. If torque is greater than the maximum torque setting but less than 120%, -OL- will flash on the display where the torque reading was (as indicated in Figure 6–11), accompanied by an audible beeping sound.

POWER


TORQUE SPEED STATUS

Figure 6–11 -OL- Torque Alarm Display

B. If torque is greater than 120% of the maximum torque setting or in condition A for greater than 5 seconds, the display will flash “OVER TORQUE ALARM TSCX” (as indicated in Figure 6–12) and will be accompanied by an audible beeping sound. The alarm relay will open, excitation current will hold at last value for 3 seconds then drop to zero.

POWER


TORQUE SPEED STATUS

∗∗∗∗ ∗∗∗∗

Figure 6–12 Over Torque Alarm Message Display

6.4.3 to reSet MaxiMUM torqUe aLarM

Press any front panel button other than SHIFT. If the alarm condition is clear, the unit will return to normal operation. Although not recommended, another option would be to disable the alarm by following the alarm setup instructions in Section 6.4.1 – Instructions for Maximum Torque Alarm Setup.

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6.5 AIR FLOW ALARM

• Usedtoindicatealackofairflowfromablowerorairline

• OnlyforusewithHysteresisDynamometers

• MonitoredonlywhenthebrakeisON

• Defaultissetin“OFF”mode

6.5.1 inStrUCtionS for air fLow aLarM SetUp



3. Select ALARMS. The display should appear as follows:

POWER


TORQUE SPEED STATUS

Figure 6–13 Air Flow Alarm Setup Display

4. Press COM SETUP button to select YES.

5. Press SHIFT 5 times to complete Air Flow Alarm setup and return to the main menu.

6.5.2 air fLow aLarM aCtion

When there is a lack of air flow, the display will flash “LOW AIR FLOW” (as indicated in Figure 6–14) and will be accompanied by an audible beeping sound. The alarm relay will open and the excitation current will automatically drop to 10% of the last excitation current.

POWER


TORQUE SPEED STATUS

∗∗∗∗ ∗∗∗∗

Figure 6–14 Air Flow Alarm Message Display

6.5.3 to reSet air fLow aLarM

Press any front panel button other than SHIFT. If the alarm condition is clear, the unit will return to normal operation. Although not recommended, another option would be to disable the alarm by following the alarm setup instructions in Section 6.5.1 – Instructions for Air Flow Alarm Setup.

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6.6 WATER FLOW ALARM

• Usedtoindicatelackofwaterflow

• OnlyforusewithEddy-CurrentorPowderBrakeDynamometers


• Monitoredonlywhenthebrakeis“ON”

6.6.1 inStrUCtionS for water fLow aLarM SetUp



3. Select ALARMS.

4. Press SHIFT 2 times. The display should appear as follows:

POWER


TORQUE SPEED STATUS

Figure 6–15 Water Flow Alarm Setup Display


6. Press SHIFT 3 times to complete Water Flow Alarm setup and return to the main menu.

6.6.2 water fLow aLarM aCtion

When there is a lack of water flow, the display will flash “LOW WATER FLOW” (as indicated in Figure 6–16) and will be accompanied by an audible beeping sound. The alarm relay will open and the excitation current will automatically drop to 10% of the last excitation current.

POWER


TORQUE SPEED STATUS

Figure 6–16 Water Flow Alarm Message Display

6.6.3 to reSet water fLow aLarM

Press any front panel button other than SHIFT. If the alarm condition is clear, the unit will return to normal operation. Although not recommended, another option would be to disable the alarm by following the alarm setup instructions in Section 6.6.1 – Instructions for Water Flow Alarm Setup.

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6.7 EXTERNAL ALARM

• Usedtoshutdownsystembasedonadditionaluserinput


6.7.1 inStrUCtionS for externaL aLarM SetUp



3. Select ALARMS.

4. Press SHIFT. The display should read as follows:

POWER


TORQUE SPEED STATUS

Figure 6–17 External Alarm Setup Display


6. Press SHIFT 4 times to complete External Alarm setup and return to the main menu.

6.7.2 externaL aLarM aCtion

If the external input is at a high level, the display will flash “EXTERNAL ALARM” (as indicated in Figure 6–18) and will be accompanied by an audible beeping sound. The alarm relay will open and the excitation current will automatically drop to 10% of the last excitation current.

POWER


TORQUE SPEED STATUS

∗∗∗∗ ∗∗∗∗

Figure 6–18 External Alarm Message Display

6.7.3 to reSet externaL aLarM

Press any front panel button other than SHIFT. If the alarm condition is clear, the unit will return to normal operation. Although not recommended, another option would be to disable the alarm by following the alarm setup instructions in Section 6.7.1 – Instructions for External Alarm Setup.

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6.8 TEMPERATURE ALARM

• Toalertuserwhendynamometergetstoohotandthermalswitchopens

• OnlyavailableforusewithWBorPBdynamometers

• Default-alwaysactive

6.8.1 inStrUCtionS for teMperatUre aLarM SetUp

No setup needed.

6.8.2 teMperatUre aLarM aCtion

When the dynamometer in use becomes too hot, the display will flash “TEMPERATURE ALARM TSCX” (as indicated in Figure 6–19) and will be accompanied by an audible beeping sound. The alarm relay will open and the excitation current will immediately decrease to 10%. After approximately 3 seconds, the current wll drop to 0.

POWER


TORQUE SPEED STATUS

∗∗∗∗ ∗∗∗∗

Figure 6–19 Temperature Alarm Message Display

6.8.3 to reSet teMperatUre aLarM

Press any front panel button other than SHIFT. The alarm condition must be cleared before the unit will return to normal operation.

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6.9 ELECTRICAL ALARM

• UsedtoprotecttheDESsupply

• Monitorselectricalinput(mains)andcircuitryoftheDES

• OnlyavailableforusewithWBorPBdynamometers

• Default-alwaysactive

6.9.1 inStrUCtionS for eLeCtriCaL aLarM SetUp

No setup needed.

6.9.2 eLeCtriCaL aLarM aCtion

When there is an electrical overload, the display will flash “ELECTRICAL ALARM TSCX” (as indicated in Figure 6–20) and will be accompanied by an audible beeping sound. The alarm relay will open and the excitation current will immediately decrease to zero.

POWER


TORQUE SPEED STATUS

∗∗∗∗ ∗∗∗∗

Figure 6–20 Electrical Alarm Message Display

6.9.3 to reSet eLeCtriCaL aLarM

Press any front panel button other than SHIFT. The alarm condition must be cleared before the unit will return to normal operation.

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7. Manually Controlled Operation

Note: Using the DSP6001 without a computer will limit its testing capabilities.

7.1 HOW TO CHOOSE DESIRED CHANNEL WHEN USING TWO DYNAMOMETERS

To select the desired channel (TSC1 or TSC2):

1. Press SHIFT.

2. Press AUX SETUP button. The display should appear as follows:

POWER


TORQUE SPEED STATUS

Figure 7–1 Dynamometer Channel Menu

3. Press POWER UNITS button until the desired channel is reached.


Note: The desired dynamometer channel must be chosen in order to continue with the following steps. All steps that are completed will be saved within that channel until the information is manually changed or the DSP6001 is reset. (To reset the DSP6001, refer to Section 9.4 – Resetting the DSP6001.)

Note: When using a dynamometer with a torque transducer or auxiliary instrument, the previous instructions will turn your TSC2 channel display “ON” allowing you to view information for both channels simultaneously.

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7.2 HOW TO SET DESIRED POWER UNITS

To select the desired power units (W, kW or HP):

1. Press SHIFT.

2. Press POWER UNITS button. The display should appear as follows:

POWER


TORQUE SPEED STATUS

Figure 7–2 Power Units Menu

3. Use UP and DOWN buttons to select desired Power Units.


7.3 HOW TO SET DESIRED TORQUE UNITS

To select the desired torque units (N.m, N.cm, N.mm, kg.cm., g.cm., lb.ft., lb.in., oz.ft., oz.in.):

1. Press SHIFT.

2. Press TORQUE UNITS button. The display should appear as follows:

POWER


TORQUE SPEED STATUS

Figure 7–3 Torque Units Menu

3. Use UP and DOWN buttons to select desired Torque Units.


7.4 HOW TO SET TORQUE CONTROL

1. Beginning with the brake in the OFF position, press the TORQUE SET button. The display should appear as follws:

POWER


TORQUE SPEED STATUS

Figure 7–4 Torque Control Menu

2. Use UP and DOWN buttons and the Decrease/Increase dial to adjust the setpoint to zero.

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Note: If the response is too slow or oscillatory, adjust the values for P, I and D. (For more detailed instruction, refer to Chapter 5– PID Settings.)

Caution: do not exCeed the Capabilities of the dynamometer or the power sourCe in use. motors draw very large Currents when held at loCked rotor and overheating may result. when using torque Control, induCtion motors Cannot be tested beyond breakdown, exCept at loCked rotor. refer to Section 7.5 – How to Set Speed control.

7.5 HOW TO SET SPEED CONTROL

Note: When using speed control, motors between 0 and 100 rpm cannot be tested unless the dynamometer is equipped with an optional, high resolution speed encoder.

1. Beginning with the brake in the OFF position, press SHIFT.

2. Press MAX SPEED button. The display should appear as follows:

POWER


TORQUE SPEED STATUS

Figure 7–5 Max Speed Menu

3. Use UP and DOWN buttons and the Decrease/Increase dial to set a value equal to or slightly greater than the free-run speed of the motor under test.

Note: PID values should be set at this time. See Section 5.5 – Setting the Correct PID’s for Your Motor.

3. Use the BRAKE ON/OFF button to turn the brake ON.

4. Start the motor under test.

5. Press the TORQUE SET button and adjust the set point to the desired load.

6. Check the torque display to make sure that the dynamometer loads the motor under test to that torque load.

Desired Results

The dynamometer should load the motor under test to the load point quickly with little or no overshoot when the BRAKE function cycles ON or OFF.

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4. Press the SHIFT button to exit the MAX SPEED function.

5. Press the SPEED SET button.

6. Use UP and DOWN buttons and the Decrease/Increase dial to set a speed equal to the max. speed.

Note: PID values should be set at this time. See Section 5.5 – Setting the Correct PID’s for Your Motor.

7. Use the Brake ON/OFF button to turn the brake ON.

8. Start the motor under test.

9. Press the SPEED SET button and adjust the set point to the desired speed.

Note: If the response is too slow or oscillatory, adjust the values for P, I and D. For more detailed instruction, refer to Chapter 5 – PID Settings.

7.6 HOW TO SET OPEN LOOP CONTROL

1. Beginning with the brake in the OFF position, press and hold the TORQUE SET button until a second beep is heard. The open loop control menu should appear. See Figure 5–2 Open Loop Contol Menu.

2. Use UP and DOWN buttons and the Decrease/Increase dial to set a value of current equal to the percent of full scale output.

3. If needed, POWER UNITS and DISPLAYED UNITS can be changed while in OPEN LOOP mode. (For further instruction, refer to Section 7.2 – How to Set Desired Power Units.)

4. Use the BRAKE ON/OFF button to turn the brake ON. (Note: When the brake is on, the only thing that can be adjusted is the set point. There are no other active settings at this time.)

5. To exit the Open Loop Control mode and return to the main menu, turn the brake OFF and press and hold the TORQUE SET button until a second beep is heard.

Desired Results

The dynamometer should load the motor under test to the desired speed quickly with little or no overshoot when the BRAKE button is cycled ON or OFF.

Desired Results

The dynamometer should load the motor under test. Because the mode is open loop, the controller will not stabilize on speed or torque, but will apply a constant current to the dynamometer brake. The actual loading will change as the brake heats up or as other external factors change. The PID’s have no effect in this mode.

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8. Computer Controlled Operation

The DSP6001 can be used with a computer to control a dynamometer and to transmit data from the motor testing device directly to the computer. Using the DSP6001 with a computer enables the unit to perform at its full capacity.

8.1 ABOUT THE GPIB INTERFACE

(General Purpose Interface Bus)

Magtrol instruments use the GPIB (IEEE-488 Standard) for computer-to-instrument interfacing because:

• TheGPIBparallelinterfaceisfasterthanserialinterfaces.

• TheGPIBenablestesterstoaccessupto15instrumentsononeport.Becausetypicalmotortesting requires that at least five separate parameters be synchronized, a system of easy, fast access to more than one instrument is essential.

• TheGPIBhasrigiddataformattingandhardwarestandards.Thesestandardshelptoensurethat all functions will work properly when the hardware and software are installed.

Note: The GPIB interface is not standard on most computers. An interface card and driver software must be installed. An IEEE-488 cable must also be installed between the computer and the DSP6001. Magtrol recommends National Instruments Corporation hardware and software.

8.1.1 inStaLLing tHe gpiB (ieee-488) ConneCtor CaBLe

Caution: make sure both the Computer and dsp6001 are turned off before installing the gpib ConneCtor Cable.

1. Connect one end of a high-quality, double-shielded cable to the DSP6001 GPIB connector.

2. Connect the other end to the GPIB interface in your PC

DYNAMOMETER / TSC1

AUX / TSC2

SUPPLY 2


BRAKE


OUTPUTCTRL OUT

BRAKE FUSE


EARTHGROUND



PC

M-TEST

Figure 8–1 GPIB Installation

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8.1.2 CHanging tHe gpiB priMary aDDreSS

Each instrument serviced by the GPIB has its own Primary Address code, which enables the computer to obtain readings from the instrument. The factory default of the setting on the DSP6001 is 09.

Some PC interfaces can access from one to fifteen 4-bit primary addresses. Other interfaces can access as many as thirty-one 5-bit primary addresses. The DSP6001 uses the 4-bit format. For setup, follow the steps below.

1. Press the SHIFT button and release.

2. Press the COM SETUP button. The display should appear as follows:

POWER


TORQUE SPEED STATUS

Figure 8–2 Com Setup Menu Display

3. Press the button below the GPIB display until the desired primary address is reached (range 0-15).

4. Press SHIFT to exit and return to main menu.

8.2 ABOUT THE RS-232 INTERFACE

The DSP6001 is equipped with an RS-232 (serial) interface that communicates with the host computer through a DB-9 interface connector. The connector pin-out consists of 2-TX, 3-RX and 5-GND.

5. GND

1.

6.

9. N/C

3. RX

8.

2. TX

4.

7.

14 3 25

69 8 7

Figure 8–3 RS-232 Interface

8.2.1 ConneCtion

The RS-232 connection includes null modem wiring internal to the unit. To install, use a straight through pin-to-pin connector cable, which can be purchased from your local electronics store.

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Note: If the desired results did not occur, please see Chapter 10 – Troubleshooting.

DIGITAL GROUND

4.

2. 3.

6.

1.

5.

7. 8. 9.

DSP6001 PC

5. GND (SIGNAL GROUND)

1. DCD (DATA CARRIER DETECT)

6. DSR (DATA SET READY)

3. TX (TRANSMIT DATA) 2. RX (RECEIVE DATA)

4. DTR (DATA TERMINAL READY)

9. RI (RING INDICATOR) 8. CTS (CLEAR TO SEND) 7. RTS (REQUEST TO SEND)

TXRX

N/C

GND

Figure 8–4 Straight Through Pin-to-Pin Cable Connection

8.2.2 CoMMUniCation paraMeterS

• Noparity

• 8databits

• 1stopbit

8.2.3 BaUD rate

There are several different baud rates to choose from including 300, 600, 1200, 2400, 4800, 9600 and 19200. To set up the desired baud rate, follow the instructions below.

1. Press SHIFT and release.

2. Press the COM SETUP button. The display will appear as shown in Figure 8–2 Com Setup Menu Display.

3. Press the button under the RS-232 BAUD display until the desired baud rate is reached.


8.3 CHECKING THE DSP6001-TO-PC CONNECTION

Note: Make sure that the DSP6001 and its host computer are communicating before acquiring data.

1. Make sure the primary GPIB address is set correctly for the DSP6001.

2. Set the input variable to 15 characters (13 variable characters and the two required data termination characters CR and LF. See Section 8.5 – Programming.)

3. Issue output data command “OD” and read 15 characters according to the instructions for your GPIB interface or serial.

Desired Results

• Torque/speeddatawillbereturned.

• TheerrormessageI/OERRORdoesnotappearonthedisplaypanel.

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8.4 DATA FORMAT

Speed-torque data is a fixed-length string in ASCII format with a floating point decimal. Use the following string format:

SdddddTdddd.R(cr)(lf)

Or

SdddddTdddd.L(cr)(lf)

Where…

S = Speed in rpm. (No leading zeroes are used.)

d = Decimal digit 0 through 9.

T = Torque in units selected during setup. (The torque value always contains a decimal point.)

L = Counterclockwise dynamometer shaft rotation (left).

R = Clockwise dynamometer shaft rotation (right).

. = Decimal point. (The decimal point location depends on the specific dynamometer and torque range in use.)

Note: When an “A” is in the R/L position (e.g. SdddddTdddd.A(cr)(lf)), it is an indication that the unit is in an alarm condition.

Note: The (cr) and (lf) characters will not display.

EXAMPLE

If a motor is running at 1725 rpm clockwise, with the dynamometer loading the motor to 22.6 oz.in., the DSP6001 will return:

S 1725T22.60R

By manipulating the string, the speed-torque and shaft direction (if required) can be extracted. Then separate numerical variables can be assigned to them for data processing.

8.5 PROGRAMMING

Note: Check the manual provided with your software for full instructions.

8.5.1 Data terMination CHaraCterS

Use the following information to answer the formatting questions asked when installing your GPIB software. All GPIB data acquisition systems require the use of data termination characters. The DSP6001 uses the GPIB standard termination characters Carriage Return (CR) and Line Feed (LF). Provide them in that order.

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8.5.1.2 Codes for CR - LF

BASIC HEX DECCR = CHR$(13) 0D 13LF = CHR$(10) 0A 10

8.5.2 tiMeoUt

Set the timeout for at least one second if asked to set a communication fault delay timeout.

Note: If the communication fault delay timeout is too short, or if the computer resets the interface too quickly, the host instrument may stop responding.

8.6 DSP6001 COMMAND SET

When entering a command code:

1. Type all characters in uppercase ASCII format.

2. End all commands with a CR-LF (hex 0D-0A).

3. Do not string multiple commands together in one line.

The character # represents a floating-point numerical value following the command. Leading zeroes are not required.

Note: If a command is not recognized, the I/O ERROR message will appear in the Status Display accompanied by a beep.

8.6.1 aLarM CoMManDS

Command Code Function Explanation

ALA# Enables or disables air flow alarm.

Values for # are: 0 = disable 1 = enable

ALE# Enables or disables external alarm.


ALL# Enables or disables all alarms. Values for # are: 0 = disable 1 = enable

ALP# Sets power alarm. Sets maximum power in kilowatts. Range is 0 to 99,999. Setting is applied to current channel.

ALS# Sets speed alarm point. Sets maximum speed in rpm. Range is 0 to 99,999. Setting is applied to current channel.

ALT# Sets torque alarm point. Sets maximum torque in input units. Range is 0 to 10,000. Setting is applied to current channel.

ALW# Enables or disables water flow alarm.


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8.6.2 CoMMUniCation CoMManDS


*IDN? Returns Magtrol Identification and software revision.

OA Prompts to return to auxiliary input data string.

Output Auxiliary prompt to return the value at the AUX INPUT x AUX SCALING factor with this format:

AxxxxxxcrlfOD Prompts to return speed-

torque-direction data string.Output Data prompt to return data string with this format:

SxxxxxTxxxxxRcrlfor

SxxxxxTxxxxxLcrlfor

SxxxxxTxxxxxAcrlfR or L is the shaft direction indicator, as viewed looking at the dynamometer shaft where: R = right; clockwise (CW) L = left; counterclockwise (CCW) A = alarm conditionThe speed will equal the displayed value and the torque will be in the same units as displayed on the front panel.

OR Prompts to return direction bit of TM2XX.

“Output Rotation” prompt to return the value at the direction input with this format: 0crlf = clockwise 1crlf = counterclockwise

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8.6.3 raMp CoMManDS

Command Code

Function Explanation

DILXX.XX Sets dynamic scale coefficient. When using dynamic scaling, XX.XX is multiplied by the I term to give the end I value.

DPLXX.XX Sets dynamic scale coefficient. When using dynamic scaling, XX.XX is multiplied by the P term to give the end P value.

DS# Enable or disables dynamic scaling.


PD# Sets ramp down rate to #RPM per second.

Specify speed range (F#) AND a stop speed (S#) before using this command. This command programs a decreasing shaft speed at a rate of #rpm per second. Once initiated, the Controller will load to locked rotor unless instructed to do otherwise.

PR • Resets ramp up or down. • Sets speed to maximum speed.• Turns brake off.

This command resets the ramp function, halting the ramp’s progress, and returns the motor to free run.

PU# Sets ramp up rate to #RPM per second.

Specify speed range (F#) AND a start speed (S#) before using this command. This command increases the shaft speed at a rate of #rpm per second.

S# Sets start or stop speed for ramp to #RPM.

When this command is used with the PD (Program Down) command, the Controller will ramp down to this speed and halt. When this command is used with the PU (Program Up) command, the Controller will load immediately to this speed and ramp up to free-run.

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8.6.4 SetUp CoMManDS


AF1# Sets the analog filter for TSC1. Values for # are: 0 = OFF 1 = 10 Hz 2 = 25 Hz 3 = 50 Hz 4 = 3 Hz

AF2# Sets the analog filter for TSC2. Values for # are: 0 = OFF 1 = 10 Hz 2 = 25 Hz 3 = 50 Hz 4 = 3 Hz

BT# Sets the brake type for TSC1. Values for # are: 0 = HD 1 = WB 2 = PB

DIN1# Selects instrument type connected to TSC1.

Values for # are: 0 = HD 1 = WB 2 = PB 3 = BRAKE

DIN2# Selects instrument type connected to TSC2.

Values for # are: 0 = AUX 1 = WB 2 = PB 3 = TM2XX

M# Enables or disables front panel controls.

Values for # are: 0 = disable 1 = enableNOTE: The brake ON/OFF switch on the front panel still functions.

NS# Sets nominal speed for WB Dynamometer.

Range is 0 to 99,999. Setting is applied to current channel.

R Resets as follows:• Manual control ON. • Brake OFF.

Use this command to cancel any previous commands.Note: These settings are the power-on default settings.

SFC# Enables or disables cross loop function.


SFT# Enables or disables tandem function.


TSC1 Selects TSC1 to be the channel that the control loop closes on.

The TSC1 or TSC2 command should be the first command sent during testing. All commands thereafter will be applied to that channel.

TSC2 Selects TSC2 to be the channel that the control loop closes on.

TSF1# Sets scale factor for TSC1. Range is 0 to 99,999.TSF2# Sets scale factor for TSC2. Range is 0 to 99,999.

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UA# Sets auxiliary input scaling to #.

This command sets the scaling factor for the auxiliary input to # units/volt. The range is 0.0 to 10000.0. Programmed value # is not saved at power down.

UE# Sets encoder pulse count to #. This command selects the pulse count option for speed transducing. Values for # are: 0 = 60-bit 1 = 600-bit 2 = 6000-bit 3 = 20-bit 4 = 30-bit 5 = 1-bit 6 = 2-bit 7 = 6-bitProgrammed value # is not saved at power

down.UI# Sets dynamometer torque

units to #.NOTE: For Hp and watts calculations to be correct, the correct dynamometer torque units must be specified. Values for # are: 0 = oz.in. 1 = oz.ft. 2 = lb.in. 3 = lb.ft. 4 = g.cm. 5 = kg.cm. 6 = N.mm. 7 = N.cm. 8 = N.m.Torque units default to 0 (oz.in.) if out of range.Programmed value # is not saved at power down.

UR# Sets readout torque units to #. This command sets the torque unit conversion for the torque readout. Values for # are 0 = oz.in. 1 = oz.ft. 2 = lb.in. 3 = lb.ft. 4 = g.cm. 5 = kg.cm. 6 = N.mm. 7 = N.cm. 8 = N.m.Torque units default to 0 (oz.in.) if out of range.Programmed value # is not saved at power down.

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8.6.5 SpeeD CoMManDS


F# Sets maximum speed to # rpm. Sets a speed range for the Controller. Must be specified before using the speed or ramp mode.

G# Sets maximum speed excited of PB.

Range is 0 to 10,000.

N • Resets speed point to maximum speed.• Sets speed mode OFF.• Sets brake OFF.

Use this command, sent alone, to reset any previous speed-stabilized setting to the maximum speed range.

N# • Sets speed point to #.• Sets brake ON.

Use this command to load the motor under test to a specific speed value #. Issue a speed range command (F#) first for best dynamic response. The Controller is functioning with the dynamometer as a closed loop system. Adjust the speed PID values to tune the response.

ND# Sets speed derivative to #. Derivative value # can be any number from 0 to 99.

NDS# Used as a multiplier for the D coefficient in the PID equation.

Values for # are A, B, C, D, E, F, G, H or I. (See Appendix F: Additional Scale Factor Table.)

NI# Sets speed integral to #. Integral value # can be any number from 0 to 99.

NIS# Used as a multiplier for the I coefficient in the PID equation.


NP# Sets speed proportional to # gain.

Proportional gain value # can be any number from 0 to 99.

NPS# Used as a multiplier for the P coefficient in the PID equation.


8.6.6 torqUe CoMManDS


Q • Resets torque to 0.0.• Turns torque mode OFF.• Turns brake OFF.

This command resets any previous torque-stabilized command, and returns the motor to free run.

Q# • Sets torque point to #. • Turns brake ON.

This is a closed loop command with its own set of PID parameters. The units defined will be the same as those displayed by the Controller.

QD# Sets torque derivative to #. Derivative value # can be any number from 0 to 99.

QDS# Used as a multiplier for the D coefficient in the PID equation.


QI# Sets torque integral to #. Integral value # can be any number from 0 to 99.

QIS# Used as a multiplier for the I coefficient in the PID equation.


QP# Sets torque proportional to # gain.

Proportional gain value # can be any number from 0 to 99.

QPS# Used as a multiplier for the P coefficient in the PID equation.


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8.6.7 MiSCeLLaneoUS CoMManD


DIR# Selects/Deselects the quadrature input circuitry. User has access to up/down counter via OH1 command. The displayed rpm is sent to the GPIB/RS-232 and applied to the PID Loop.NOTE: Only applies to DSP6001 Revision 7.5 and later versions.

Values for # are: 0 = for single frequency 1 = for quadrature input

I# Sets current output to #. The power supply outputs a fixed value of current. Use any value # between 0 and 99.99%. (99.99% = 1 Amp).

IOXX.XX Applies an offset to the output DAC on channel 1 only. Used to clamp motor speed prior to testing.NOTE: Only applies to DSP6001 Revision 7.6 and later versions.

Values for # range from 0 to 99.99.

OH1 Returns quadrature counter information.

Two 24-bit hex values are returned. The first value is the up/down count. The second value is an unused value.

SAVE Saves present configuration of unit to non-volatile memory.

X Prompts to return % current output. This command returns the % current value in the format “I##.##”. The value will be between 0 (no loading) and 99.99 (full loading).

Note: For further reference, see Appendix F – Remote Configuration Flow Charts.

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9. Calibration

9.1 CLOSED-BOX CALIBRATION

The DSP6001 features closed-box calibration. The advantage of closed-box calibration is that the user does not have to disassemble the case or make mechanical adjustments.

9.2 CALIBRATION SCHEDULE

Calibrate the DSP6001:

• Afteranyrepairsareperformed.

• Atleastonceayear;morefrequentlytoensurerequiredaccuracy.

9.3 BASIC CALIBRATION PROCESS

The basic calibration process consists of four procedures which must be performed in the following order:

1. Initial Calibration Procedure

2. TSC1 Offset and Gain

3. TSC2 Offset and Gain

4. DAC Output Offset and Gain

5. Speed Check

6. Decimal Point Check

Items needed for calibrating the DSP6001:

• Externalvoltagereferenceof0to5voltsDC

• Digitalmultimeter(DMM)

Both instruments should have a VDC accuracy of 0.05% or better.

9.3.1 initiaL CaLiBration proCeDUre

1. Allow the DSP6001 to stabilize in an environment with:

• Anambienttemperatureof18°Cto25°C.

• Relativehumiditylessthan80%.

2. Turn on the DSP6001.

3. Allow the DSP6001 to warm up for at least 30 minutes.

4. Enable the calibration mode as follows:

• TurninstrumentpowerOFF.

• PressinandholdtheUP and DOWN buttons simultaneously.

• TurninstrumentpowerON.

• ContinuepressingtheUP and DOWN buttons until the display shows the software revision date then release.

The front panel displays the actual correction factors above the ZERO and GAIN readouts (see Figure 9–1 Calibration Display Analog Inputs).

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POWER


TORQUE SPEED STATUS

Figure 9–1 Calibration Display Analog Inputs

Note: To exit CALIBRATE mode without making any changes, press the SHIFT button 8 times.

9.3.2 tSC1 offSet anD gain

1. Connect the external voltage reference common to Pin 13 of the TSC1 input connector.

2. Connect the external voltage reference high to Pin 14 of the TSC1 input connector.

14. TORQUE SIGNAL13. TORQUE COMMON12. D.P. B11. INDEX10. TACH. A 9. D.P. A 8. +5.0 VDC COM

7. +5.0 VDC 6. -24 VDC 5. -24 VDC COM 4. +24 VDC COM 3. +24 VDC 2. TACH. B 1. FLOW/CLUTCH

14 3 2

891011

6 5

1213

7

14

Figure 9–2 TSC1 Input Connector

3. Apply +0.000 VDC.

4. Press the ZERO button.

5. Adjust the ZERO by turning the Decrease/Increase Dial until the displayed voltage equals the reference voltage (within 00.10 mV).

Note: The magnitude of change per revolution can be increased by pressing the UP button or decreased by pressing the DOWN button.

6. Apply 5.0 VDC.

7. Press the GAIN button.

8. Adjust the Decrease/Increase Dial until the displayed voltage equals the reference voltage within 00.10 mV.

9. Press SHIFT to proceed to Section 9.3.3 – TSC2 Offset and Gain.

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9.3.3 tSC2 offSet anD gain

1. Connect the external voltage reference common to Pin 13 of the TSC2 input connector.

2. Connect the external voltage reference high to Pin 14 of the TSC2 input connector.

11. N/C10. TACH. C 9. ROT_SENS 8. +5.0 VDC COM

14. TORQUE SIGNAL13. TORQUE COMMON12. BITE

6. -24 VDC

3. +24 VDC 2. N/C

5. -24 VDC COM 4. +24 VDC COM

1. SPARE

7. +5.0 VDC

14 3 2

891011

6 5

1213

7

14

Figure 9–3 TSC2 Input Connector

3. Apply +0.000 VDC.

4. Press the ZERO button.

5. Adjust the ZERO by turning the Decrease/Increase dial until the displayed voltage equals the reference voltage (within 00.10 mV).

Note: The magnitude of change per revolution can be increased by pressing the UP button or decreased by pressing the DOWN button.

6. Apply 5.0 VDC.

7. Press the GAIN button.

8. Adjust the Decrease/Increase dial until the displayed voltage equals the reference voltage within 00.10 mV.

9.3.4 DaC oUtpUt offSet anD gain

1. Beginning in the TSC2 Offset and Gain screen, press SHIFT to proceed to the Calibration Output DAC Display Menu. The display should appear as follows:

POWER


TORQUE SPEED STATUS

Figure 9–4 Calibration Output DAC Display Menu

2. Connect meter to Pin 14 (negative) and Pin 7 (positive) of SUPPLY 1 connector.

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15. N/C14. CURRENT SET POINT (ANALOG 0V)13. +5.0 VDC COM12. SUPPLY +24 VDC11. STAND-BY CHANNEL 110. TEMPERATURE ALARM CHANNEL 1 9. SHIELD (EARTH) 8. W FLOW_1 7. CURRENT SET POINT (SIGNAL) 6. +5.0 VDC COM 5. SUPPLY +24 VDC 4. PRIMARY SUPPLY CONTR. CHANNEL 1 3. N/C 2. ELECTRICAL ALARM CHANNEL 1 1. SHIELD (EARTH)

14 3 25

912 11 10

68 7

14 1315


3. Using the Decrease/Increase dial, adjust the value so that the meter reading is 0.000 volts or within 00.20 mV.

4. Press SHIFT once.

5. Connect meter to Pin 14 (negative) and Pin 7 (positive) of SUPPLY 2 connector.

3. CLUTCH

8. W FLOW_2

11. STAND-BY CHANNEL 2

1. SHIELD (EARTH) 2. ELECTRICAL ALARM CHANNEL 2

4. PRIMARY SUPPLY CONTR. CHANNEL 2 5. SUPPLY +24 VDC 6. +5.0 VDC COM 7. CURRENT SET POINT (SIGNAL)

9. SHIELD (EARTH)10. TEMPERATURE ALARM CHANNEL 2

15. N/C

13. +5.0 VDC COM14. CURRENT SET POINT (ANALOG 0V)

12. SUPPLY +24 VDC

14 3 25

912 11 10

68 7

14 1315



7. Press SHIFT once. The display should appear as follows:

POWER


TORQUE SPEED STATUS

Figure 9–7 Calibration Accessory Torque DAC Display Menu

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8. Connect volt meter to Pin 3 (negative) and Pin 1 (positive) of ACCESSORY TORQUE-SPEED OUTPUT.

7 6

3 1

5 42

8

8. +5.0 VDC COM7. EXTERNAL ALARM INPUT6. ALARM RELAY (COMMON)5. ALARM RELAY (NORMALLY CLOSED)4. ALARM RELAY (NORMALLY OPEN)3. ANALOG GROUND2. ANALOG SPEED1. ANALOG TORQUE

Figure 9–8 Accessory Torque-Speed Output



11. Using the Decrease/Increase dial, adjust the value so that the meter reading is 9.000 volts or as close as possible.

12. Press SHIFT once. The display should appear as follows:

POWER


TORQUE SPEED STATUS

Figure 9–9 Calibration Accessory Speed DAC Display Menu

13. Connect volt meter to Pin 3 (negative) and Pin 2 (positive) of the ACCESSORY TORQUE-SPEED OUTPUT.



16. Using the Decrease/Increase dial, adjust the value so that the meter reading is 9.000 volts or as close as possible.

17. Press SHIFT once to end calibration and return to main menu.

9.3.5 SpeeD CHeCk

1. Connect a function generator with square wave TTL output to pins 10 (TACH. A) and 8 (+5.0 VDC COM) of the 14-pin TSC1 connector. For reference, see Figure 9–2 TSC1 Input Connector.

2. Verify that the speed display reads the same value as the function generator frequency.

3. If the speed display does not read the same value as the function generator, call Magtrol customer service.

Note: There are no adjustments for speed calibration.

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9.3.6 DeCiMaL point CHeCk

1. Connect a 0.5 VDC source to pins 14 (TORQUE SIGNAL) and 13 (TORQUE COMMON) of the 14-pin TSC1 connector. For reference, see Figure 9–2 TSC1 Input Connector.

2. Verify that the torque display reads 500.0.

3. Connect pin 9 (D.P. A) to pin 8 (+5.0 VDC COM).


5. Disconnect pin 9 from pin 8.

6. Connect pin 12 (D.P. B) to pin 8 (+5.0 VDC COM).


8. If the torque display does not show correct readings, call Magtrol Customer Service.

Note: There are no adjustments for decimal point location.

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10. Troubleshooting

If you require additional assistance, please contact Magtrol Customer Service at 1-716-668-5555.

Problem Reason SolutionDisplay indicates I/O ERROR.

Command does not match the unit’s programmed set of instructions.

Use correct command and format.

Speed command sent, but Controller does not respond.

Communication occurred but the Controller is not loading the motor.

Adjust PID values.

Mechanical power reads much higher or lower than expected

Torque units are incorrect. Set torque input units to match the specifications on dynamometer nameplate.

No GPIB communication. Setup error and/or hardware fault.

Check:• GPIB address of Controller.• GPIB cable - should be functioning and attached to Controller and computer interface card.

No RS-232 communication.

Setup error and/or hardware fault.

Check:• Baud rate of Controller.• Pinout of serial cable.• Cable attachment to Controller and serial interface port of computer.

Dynamometer shaft does not turn smoothly when BRAKE is OFF.

Salient poles were set up on the rotor by having brake current applied with no shaft rotation.

Start the motor and bring up to speed. Press BRAKE button ON. Adjust output current up to a value at least 25% of the maximum torque rating of the dynamometer in use (if possible). Reduce output current to 0.

Dynamometer loads too quickly causing motor to stall.

Input units are improperly set up.

Set torque input units to match specifications on dynamometer nameplate.

Speed not reading correctly.

Speed encoder is improperly set up.

Set speed encoder bits to match specifications on dynamometer nameplate.

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Appendix A: LabVIEW Programming Examples

0 [0..1] 1 [0..1]

Magtrol offers a comprehensive motor testing software program to satisfy most of your programming needs. To order your software, call Magtrol Sales at 1-716-668-5555.

A.1 SIMPLE READ

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0 [0..2] 1 [0..2]

1 [0..2] 2 [0..2]

A.2 TORQUE STABILIZED

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A.3 SPEED STABILIZED

0 [0..2] 1 [0..2]

2 [0..2] 2 [0..2]

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Appendix B: Inertia Correction

B.1 INERTIAL EFFECT ON MOTOR TEST DATA

A major advantage of the DSP6001 is its ability to obtain full motor performance data (free run to locked rotor) by continuous load application with an absorption dynamometer. Data acquisition is fast, resulting in minimal motor I2R losses, and loading characteristics simulate actual end-use applications.

When a motor is accelerating or decelerating, the measured torque is the sum of the true motor torque ± the inertial torque or stored energy of the system. Unless inertial torque is excluded, motor performance will vary in proportion to the rate of acceleration or deceleration.

This type of error can produce problematic test results. For example, during rapid deceleration, system inertia can produce apparent efficiency greater than 1.0. This error may occur if output power is divided by input power without extracting the stored energy in the system.

Since “inertial effect” is only a factor when speed is changing, and because inertial torque is proportional to the rate of change, inertial value may be expressed as a unit of torque per change in rpm in a given period of time. With the DSP6001, properly adjusted PID values yield constant change in rpm so that the inertial torque can be expressed as a constant.

B.2 PROCEDURE FOR INERTIA CORRECTION

1. Determine the torque Correction Factor (CF) as follows:

• AdjustthePIDloopproperly

• Establishatorquevalueequaltotheinertialtorque.

2. Use the “Program Down” command (PD#) to ramp to 75% of the free-run speed.

3. Select a data point on the performance curve where speed will be approximately 78% of the free-run speed. Let this represent the dynamic speed-torque value.

4. Immediately program your DSP6001 (Nddddd) to a speed equal to the dynamic speed value. When the speed stabilizes, use this as the static torque value.

CF = Dynamic Torque - Static Torque

To correct your data, subtract the CF from each torque point obtained during the ramp.

Example:

FR

0TORQUE

DYNAMICTORQUE VALUE

SPEED VS TORQUECURVE WITH CONSTANTDECELERATION

78% OF FR

STATIC TORQUEVALUE

CF = DIFFERENCE IN TORQUE

SPEED

DIFFERENCE IN TORQUE

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B.2.1 key ConDitionS

• Select appropriate value. The test point selection of 78% is typical for an induction motor. Use a value in the linear portion of the motor curve where there is a substantial torque change with speed.

• Acquire data rapidly. Rapid data acquisition is necessary so that motor heating does not degrade performance by adding a false difference between the static and dynamic torque values.

• Use a regulated power source. The input line voltage must be stable for the time necessary to perform the test. Torque varies by the square of the change in line voltage.

• Obtain new CF value for various deceleration/ acceleration rates. The CF is only valid for its specific ramp rate. To calculate other CF rates, use the following equation:

CFnew

= (CFold

/ramp rate) × new ramp rate

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Appendix C: Front Panel/Display Menu Flow Charts


POWER

POWER


TORQUE SPEED STATUS

DECREASE INCREASE

UPDIP


SPEED SET

MAX SPEED

TORQUE SET

TORQUE UNITS

BRAKE ON/OFF

POWER UNITS

DOWN

The following flow charts are a reference for navigating through the key functions of the DSP6001 Dynamometer Controller. For step-by-step setup instructions, refer to the corresponding chapters in this manual.

C.1 PRIMARY KEY FUNCTIONS

ON

OFF

BRAKEON/OFF

TORQUESET

0.000–99,9992.

P 0–99%4.

I 0–99%5.

D 0–99%6.

SPEEDSET

0.000–99,9993.

1.

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C.2 SECONDARY KEY FUNCTIONS

C.2.1 power UnitS MenU

POWERUNITSSHIFT

W

Hp

kW

C.2.2 torqUe UnitS MenU

TORQUEUNITSSHIFT

N.m

N.cm

N.mm

kg.cm

g.cm

lb.ft.

lb.in.

oz.ft.

oz.in.

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C.2.4 aUx SetUp MenU

AUXSETUP

SHIFT

CLOSELOOP ON

SPEED DAC

TORQUEDAC

0.000–99,000UNITS/V

TSC1

TSC2

0.000–99,999RPM/V

DISPLAY

ON

OFF(If

AUX or

TM2X

X

on T

SC2)

(If Other)

C.2.3 Max SpeeD MenU

MAXSPEEDSHIFT 0.000–99,999

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C.2.5 CoM SetUp MenU

COMSETUPSHIFT

RS-232BAUD

BITE(If TM 2XXon TSC2)

GPIBADDRESS

CONTRAST

19,200

9600

4800

2400

1200

600

300

0 – 15

0 – 3

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C.2.6.1 MaxPower Setup Menu

SHIFT DYNOSETUP

MAXPOWER

TSC1/TSC2

MAXPOWER

TSC1

TSC2

0.000–99,999kW

C.2.6 Dyno SetUp MenU

Note: Refer to the flow charts on the following pages for a more detailed breakdown of MaxPower, Dynamometer, Encoders and Alarms.

DYNOSETUP

SHIFT

MAX POWER

DYNAMOMETER

ENCODERS

ALARMS

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C.2.6.2 Dynamometer Configuration Menu

Note: Refer to flow charts C.2.6.2A through C.2.6.2H for a more detailed breakdown based on test instrument selection. All flow charts will be a continuation of C.2.6.2 beginning at SHIFT*.

DYNOSETUP

TSC2

SHIFT WB

PB

TM2XX

AUX

FILTER

10 Hz

25 Hz

50 Hz

OFF

FILTER

10 Hz

25 Hz

50 Hz

OFF

TSC1

HD

WB

PB

BRAKE

SHIFT *

DYNAMOMETER

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C.2.6.2A Hysteresis Dynamometer Setup Menu

INPUTUNITS

SHIFT

N.m

N.cm

N.mm

kg.cm

g.cm

MAXTORQUE

0.000–10,000

lb.ft.

lb.in.

oz.ft.

oz.in.

SHIFT

SCALEFACTOR

MAXTORQUE

0.000–10,000

0.000–99,999

C.2.6.2B Torque Transducer Setup Menu

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ICE

S

C.2.6.2C Aux Setup Menu

SHIFTSCALE

FACTOR0.000–99,999

C.2.6.2D Eddy-Current Dynamometer Setup Menu

SHIFT

SCALEFACTOR

MAXTORQUE

0.000–10,000

SHIFTNOMINAL

SPEED0.000–10,000

0.000–99,999

C.2.6.2E Powder Dynamometer Setup Menu

SHIFT

SCALEFACTOR

MAXTORQUE

0.000–10,000

0.000–99,999

96


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S

C.2.6.2F Eddy-Current Dynamometer with Eddy-Current Dynamometer (Tandem Setup)

SHIFTTSC1

SCALEFACTOR

MAXTORQUE

0.000–10,000

SHIFT

NOMINALSPEED

0.000–10,000

0.000–99,999

SHIFTTSC2

SCALEFACTOR

MAXTORQUE

0.000–10,000

SHIFT

NOMINALSPEED

0.000–10,000

SHIFT

TANDEMCONFIG-URATION

SHIFT

0.000–99,999

NO

YES

97


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PE

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ICE

S

C.2.6.2G Powder Brake Dynamometer with Powder Brake Dynamometer (Tandem Setup)

SHIFTTSC1

SCALEFACTOR

MAXTORQUE

0.000–10,000

0.000–99,999

SHIFTTSC2

SCALEFACTOR

MAXTORQUE

0.000–10,000

0.000–99,999

SHIFT


SHIFT

NO

YES

98


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S

C.2.6.2H Eddy-Current Dynamometer with Powder Brake Dynamometer (Tandem Setup)

SHIFTTSC1

SCALEFACTOR

MAXTORQUE

0.000–10,000

SHIFT

NOMINALSPEED

0.000–99,999

0.000–99,999

SHIFTTSC2

SCALEFACTOR

MAXTORQUE

0.000–10,000

SHIFT


0.000–99,999

NO

YES

SHIFT

SHIFT

MAX SPEEDEXCITED

OF PB

0.000–10,000

IfTandem

99


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S

C.2.6.3 Encoder Setup Menu

ENCODERSDYNOSETUP

SHIFT

TSC1/TSC2

BITS

SHIFT

SPEEDALARM

TSC1

TSC2

20

30

6000

600

60

0.000 –99,999

100


AP

PE

ND

ICE

S

C.2.6.4 Alarm Setup Menu

AIR FLOWALARM

ALARMS

DYNOSETUP

SHIFT

YES NOSHIFT OR

EXTERNALALARM

WATERFLOWALARM

YES NOSHIFT OR

YES NOSHIFT OR

ENABLEALL

ALARMS

YES NOSHIFT OR

101

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Appendix D: Remote Configuration Flow Charts

D.1 ADVANCED CONFIGURATION

Command - ALL0Turn off all alarms while configuring unit

Command - DIN1# Select what instrument is on TSC1

Command - TSF1# Set the scale factor for TSC1

Command - RReset unit to known state

Command - SFC# Enable or disable cross loop function

Command - SFT# Enable or disable tandem function

Command - DIN2# Select what instrument is on TSC2

Command - UI# Set the input units for TSC1

Command - TSF2# Set the scale factor for TSC2

Command - BT# Set brake type on TSC1

Command - G# Select max excited speed of PB

START

A

TSC not selected yet

Command - ALA#Enable or disable air flow alarm

Command - ALE#Enable or disable external alarm

Command - ALW#Enable or disable water flow alarm

Command - TSC1 or TSC2Select TSC to control

Command - AF1# Select filter for TSC1

Command - AF2#Select filter for TSC2

Command - ALL1 Turn on all alarms

A

DONE

WAIT 6 SECONDS

102

Magtrol Model DSP6001 Dynamometer ControllerAppendix D: Remote Configuration Flow Charts

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S

D.2 PRE-TEST

START

Command - UR# Select torque readout

Command - ALS# Set speed alarm point (rpm)

Command - ALP# Set power alarm point (kw)

Command - ALT# Set torque alarm point (readout units)

Command - NS# Set nominal speed

Command - UE#Select encoder pulse count

DONE

TSC selected

103

Magtrol Model DSP6001 Dynamometer Controller Appendix D: Remote Configuration Flow Charts

AP

PE

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ICE

S

D.3 RAMP

Command - F Set max speed (calculation purposes)

START

Command - PU# or PD#Command to ramp up or down & at what rate

Command - PRTerminate ramp test

Command - S#Set start or stop speed of ramp

Command - NPS#Select P multiplier

Command - NIS#Select I multiplier

Command - NDS#Select D multiplier

Command - NP#Select P term

Command - NI# Select I term

Command - ND#Select D term

Data commands

DONE

Command - DPL#Set the dynamic scale factor for P term

Command - DIL# Set the dynamic scale factor for I term

Command - DS#Enable or disable dynamic scaling

104


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S

D.4 SPEED

START

Command - N# Set speed point

Command - N Reset speed point

Command - NPS# Select P multiplier

Command - NIS# Select I multiplier

Command - NDS# Select D multiplier

Command - NP# Select P term

Command - NI# Select I term

Command - ND# Select D term

Data commands

DONE

105

Magtrol Model DSP6001 Dynamometer Controller Appendix D: Remote Configuration Flow Charts

AP

PE

ND

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S

D.5 TORQUE

START

Command - Q#Set speed point

Command - QPS#Select P multiplier

Command - QIS#Select I multiplier

Command - QDS#Select D multiplier

Command - QP#Select P term

Command - QI#Select I term

Command - QD#Select D term

Data commands

Command - QReset speed point

DONE

106


AP

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S

D.6 MISCELLANEOUS

Command - DIR#Selects quadrature input or single frequency

Command - OH1Returns quadrature counter values

Command - IOXX.XXApplies offset to output DAC on channel 1

Command - SAVESave configuration to NVM

Command - I#Set current to #

Command - X Returns the % current value

Command - ODRequest torque and speed

of TSC under control

Command - OARequest output of TSC2 torquein Nm for TM2XX or AUX input

Command - ORRequest rotation direction of TM2XX

D.7 DATA

107

AP

PE

ND

ICE

S

Appendix E: Schematics

E.1 DYNAMOMETER POWER SUPPLY

A_

GN

D

A_

+5

VD

L7

1u

H

L8

1u

H

TP

12

TP

18

0.1

uF

C1

31+5

VD

+5

VA

1u

H

L3

1u

H

L2

TP

1

1u

FC

3

+5

VD

TP

2

AG

ND

$G_D

GN

D

$G_D

PW

R

+1

2V

-12

V

10

uF

C4

4

10

uF

C4

1 TP

16

+1

2V

-12

V0.1

uF

C4

5

0.1

uF

C4

0

TP

15A

GN

D

AG

ND

L1

C4

1u

H A_

CO

M

+2

5V

-25

V

OU

T3

1u

H

L4

1u

H

L6

1u

H

L50.1

uF

1O

UT

GND3GND4 7

1O

UT

GND1GND2 3

INU1

2

2

IN1

U1

3

IN2

6

GN

D5

IN4

IN3

8 2 3 6 7

U1 IN

1

0.1

uF

C3

9

5.1

KR

38

TP

9

5.1

KR

39

C3

7

C3

8

TP

8

47

00

uF

C3

5

1

C3

3

C3

4

1

10

00

uF

10

00

uF

0.1

uF

0.1

uF

TP

17

3.3

k

R3

7C

42

47

00

uF

GN

D2

LM

34

0-5

+3

5V

AG

ND

AC

12

+

AC

2 3 2

BR

1

-4

+

AC

2

AC

1 3

-4

BR

2

12

11 9

TX

1

78

2

+1

AC

2 3

AC

1

BR

3 -4

7 9 10

1 3 4 6

AC

_IN

2A

C_

IN1

AC

_IN

3A

C_

IN4

2

C1

1 3 4

0.1

uF

0.1

uF

C1

9

0.1

uF

C3

0

0.1

uF

C4

3

0.1

uF

C1

28

C1

27

SIG

_T

RA

NS

_1

4A

-30

-51

5

TX

2

PD

05

PE

05

PD

05

TP

11

12

6

0.1

uF

SIG

_T

RA

NS

_1

4A

-56

-28

11 2 3

J2

54

J1

2 3 4 5

1

1

MH

1

1 1

MT

G_

HO

LE

MH

2

MT

G_

HO

LE

MH

3

1 1

MT

G_

HO

LE

MT

G_

HO

LE

MH

5

MH

6

MH

4

MT

G_

HO

LE

MT

G_

HO

LE

1

HE

AD

ER

_S

IP5

HE

AD

ER

_2

EA

RT

H_

GN

D

LM

78

L1

2A

CM

LM

79

L1

2A

CM

108

Magtrol Model DSP6001 Dynamometer ControllerAppendix E: Schematics

AP

PE

ND

ICE

S

E.2 DYNAMOMETER DSP & MEMORY

PS

C_1

200

R74

34

C10

0

+25

V

1 3 4 5 6 7 8 9 102

J10

11 12 MH

1 1 2

R44 33

0

PS

2702

-1

U2013 14 15 16 17 18 19 20 21 22 23 24

MH

2

IEE

E48

8

ST

BY

_1

R76

200

R75

CLU

TC

H

ST

BY

_2

200

R77

200

R78

200

PS

C_2

4 3 4 34 343

4700

pFC

103

4700

pFC

101

4700

pFC

102

C10

5 3 2M

MB

T22

22

BIT

E ELE

C_1

ELE

C_2

TE

MP

_1

10k

R14

10k

R23

1kR92

1

+5V

D

10k

R11

10k

R2

0.01

uFC

130

0.01

uFC

121

4700

pF

Q3

1 2 1

R43

R4133

0

330

RE

LAY 1 2 1 2

R40

R42 33

0

330

2

U11

19 18 17 16 15 14 13

1Q 2Q 3Q 4Q 5Q 6Q

CS

~A

DS

CLKT

_SE

L0

T_S

EL1

R1

R15

R12

C5

TP

21

0.01

uF C7

0.01

uF

C10

TP

20

128Q U

39

19 18 17 16 15 14 13

1Q 2Q 3Q 4Q 5Q 6Q74H

C57

4

128Q 74

HC

574

7Q

CS

~D

A1

CS

~D

A2

BIT

E_1

SE

L2

7Q

PS

2702

-1

U21 PS

2702

-1

U22 PS

2702

-1

U23 PS

2702

-1

U24

22k

22k

22k

BIT

E_1

4700

pF

71D

IO8N

DIO

7N

80 91 70

DIO

5ND

IO4N

DIO

3ND

IO2N

DIO

1N

RE

NN

IFC

N

DIO

6N

74 77 88 89 92 79

DA

VN

EO

INA

TN

NS

RQ

N

XT

AL1

82 84 85 73 76

95 96

81N

DA

CN

NR

FD

N

XT

AL0

67 19 18U19

17 16 15 2 3 5 6

A3

A4

A0

A1

A2

9 10 11 50 49 47 46 44 43 42 39 55 64 63

D5

D4

D3

D6

D7

D0

D1

D2

7

D[0

-23]RE

SE

T~

RE

SE

TN

AD

DR

4A

DD

R3

AD

DR

2A

DD

R1

AD

DR

0

DA

TA

15D

AT

A14

DA

TA

13D

AT

A12

DA

TA

11D

AT

A10

DA

TA

9D

AT

A8

DA

TA

7D

AT

A6

DA

TA

5D

AT

A4

DA

TA

3D

AT

A2

DA

TA

1D

AT

A0

CS

NW

RN

RD

N

21 51

RE

MT

RIG

DC

AS

9910

0

66 28 23

1D2 3 4 5 6 7 8111

20 D4

D6

D5

D3

D2

D1

D01

D[0

-23]

KE

YC

LKN

KE

YD

QK

EY

RS

TN

TA

DC

SLA

DC

S

BB

US

_OE

NA

BU

S_O

EN

CS

~O

UT

1_IO

9

1D2 3 4 5 6 7 8111

D7

D2

D3

D4

D5

D6

D1

D0

9

2 3 5 6

D7

+5V

D

BU

SY

1A 1B 2A

IN_0 4 7

IN_1

IN_2

IN_3

1YU40

D[0

-23]

CS

~_V

FD

62 34 38 32 33 22 26 29 31 30 53

NC

52 D0

D2

D4

D6

2 4 6 8

1 3 5 7 910

D1

D3

D5

D7

J5

12 14 16

DIS

PLA

Y

1 2 6 8 19 11 13 15 174

U4 1Y

11Y

21Y

31Y

4

2Y1

2Y2

2Y3

1G 1A1

1A2

1A3

1A4

2G 2A1

2A2

2A3

+5V

D

D0

D6

D5

D4

D2

D3

D7

D1

8

11 13 15 HE

AD

ER

_16

18 16 14 12 9 7 5 3

CS

~R

EA

D_I

O

WR

~

AB

US

NB

BU

SN

INT

R

RD

Y1

DR

QD

AC

KN

CP

UA

CC

PA

GE

DS

WA

PN

BU

RS

T_R

DN

FIF

O_R

DY

MO

DE

TN

T48

82

CS

~O

UT

2_IO

1498

+5V

D

+5V

D

D6

D7

D6

D7

1

2021

D4

D3

D2

D1

D0

D2

D3

D4

D5

D0

D1

131415171819D

5

22k

R33

3 42U9 A

15A

14A

13A

12A

11A

10

A16

A14

A13

A12

A11

A10

22k

29 28 25 23 5 6 7 8 9 10 11

A9

A8

A7

A6

A5

A4

A3

A2

OE

A0

PG

M

CE

A1

A8

A7 A1

A6

A5

A4

A3

A2

A0

2427 12 31 2226A

9

VP

P

MB

M27

C10

01-1

5Z

R34

PA

GE

PB

11

31

U28

AD

S~

RO

M~

WR

~

9 10

U28

D12 13

U28

B4 5

6

74H

C0011

74H

C00

74H

C00

15 9 713 12 11 1014

CS

~_V

FD

CS

~_T

NT

488

CS

~E

EP

RO

M

CS

~O

UT

1_IO

CS

~IN

_IO

RD

~

2

74H

C00

U28

C

CS

~_V

FD

OC

2D 3D 4D 5D 6D 7D 8DCLK

OC

2D 3D 4D 5D 6D 7D 8DCLK

40M

Hz

TE

MP

_2

10k

R99

10k

R10

0 SP

AR

E

10k

R98

10k

0.01

uF

R97

C14

1

0.01

uFC

126

0.01

uF

0.01

uFC

143

0.01

uFC

144

0.01

uFC

142

0.01

uFC

16

0.01

uF

C20

6

0.01

uFC

207

0.01

uF

0.01

uFC

208

0.01

uFC

205

22k

R22

22k

R10

2

22k

R10

3

22k

R10

1

22k

R10

4+5V

D

RO

T_SE

NS

WF

LOW

1

WF

LOW

2

11 10 14 13 15 1

3A 3B 4A 4B

SE

L2

9 12

3Y 4Y ST

RO

BE

GS

ELE

CT

AB

+5V

D

74H

C15

7

IN_2

IN_1

IN_3

IN_074

HC

244

C6

C8

C13 T N

0.01

uF0.

01uF

C80

0.1u

FC

740.

1uF

0.1u

FC

600.

1uF

C97

C18

0.01

uF

R16

22k

R25

22k

22k

R13

22k

R10

0.1u

FC

590.

1uF

C11

70.

1uF

C11

80.

1uF

C11

9

R32

10k

7 47 4

0.01

uFC

125

R31

10k

R30

10k

+5V

D

7 4

0.01

uFC

129

0.01

uFC

124

0.1u

FC

140

0.1u

FC

170.

1uF

C13

4

0.01

uF

2A4

2Y4

C13

32Y

2B

A0

A1

A2

A3

A4

A5

A6

A7

1 2 3 26 4 25 5 24U14

A8

A9

A10

A11

A12

A13

A14

DQ

1D

Q2

DQ

3D

Q4

DQ

5D

Q6

DQ

7

DQ

0

237 8

219

10 11D

2112 13 15 16 17 18 19

D20

D16

D17

D18

D19

D22

D23

6

A10

A11

A9

A8

A7

A6

A5

A4

A3

A2

A1

A0

A12

A13

A14

A0

A1

A2

A3

A4

A5

A6

A7

A7

A6

A5

A4

A3

A2

A1

A0

1 2 3 26 4 25 5 24U15

A8

A9

7 8 9

A10

A11

A12

A13

A14

DQ

1D

Q2

DQ

3D

Q4

DQ

5D

Q6

DQ

7

DQ

0

A13

A14

A12

A11

A10

A9 D15

D8

D9

D13

D14

D10

D12

D11

23 21 10 11 12 13 15 16 17 18 19

6A

8

E G W 5G

2B

22 27

A1

B2

C3 6 4

G1

G2A

A13

A15

A14

A12D

S~

R S

1 2 3 4 5 6 7 8

J13

E G W

22 27

68

NC

7

OR

G

VC

C

GN

D5

DI

3

CS

1 2U3 D

O4

CLK

C96

RS

_RX

DR

S_T

XD

SC

LK

C12

2

2 6

0.1u

F

14 7 13 8

16

VC

CV

+ V-

TX

1OU

TT

X2O

UT

RX

1IN

RX

2IN

0.1u

F

SD

OU

T

MC

M62

06

93LC

66A+

5VD

2020

1 2 3 4 5

A0

A1

A2

A3

A4

A5

A6

A7

U16

A1 A7

A6

A5

A4

A3

A2

A0

26 25 24

7 8 9

A8

A9

A10

A11

A12

A13

A14

DQ

1D

Q2

DQ

3D

Q4

DQ

5D

Q6

DQ

7

DQ

0

A11

A12

A10

A9

A13

A14 D1

D0

D2

D3

D5

D7

D4

D6

23 21 10 11 12 13 15 16 17 18 19

6A

8

D[0

-23]

A[0

-15]

A15

A14

A13

A12

A11

A10 A9

A8

83 82 80 78 77 76 74 73A

8A

9A

10A

11A

12A

13A

14A

15 A3

A2

A4

A5

A6

A1

A0

D23

D22

D21

D20

D19

D18

D17

D16

A7

A6

A5

A4

A3

A2

A1

A0

71 68 65 64 63 61 60

D23

D22

D21

D20

D19

D18

D17

D16

118

117

115

114

112

111

109

108

72A

7

E G W

22 27

RD

~W

R~

A15

+5V

D

C12

0

1 3 4U37

C1+

C1-

C2+

5 11 10 12 9

C2-

TX

1IN

0.1u

F

0.1u

F

SD

IN

TX

D

RX

D

C12

3

C11

6

SD

OU

T

D14

D13

D12

D11

D10

D9

D8

D7

D0

D1

D6

D5

D4

D2

D3

D15

D14

D13

D12

D11

D10 D9

D8

106

104

103

101

100

96 95 94

D6

D5

D4

D3

D2

D1

D0

93 91 90 88 87 85 84

D7

PB

5P

B6

PB

7P

B8

PB

9P

B10

PB

11B

US

Y

PS

DS

X/Y

59 57 55

8 13 12 4 6 7 14 15 17 1810

HA

CK

/PB

14H

RE

Q/P

B13

HE

N/P

B12

HR

/W/P

B11

HA

2/P

B10

HA

1/P

B9

HA

0/P

B8

H7/

PB

7H

6/P

B6

H5/

PB

5

SR

DS

TD

PB

0P

B1

PB

2P

B3

L/R

SC

K

33 3819 21 23 24 32 35 29 28 26 2531

ST

D/P

C8

SR

D/P

C7

SC

K/P

C6

SC

2/P

C5

SC

1/P

C4

SC

0/P

C3

SC

LK/P

C2

TX

D/P

C1

RX

D/P

C0

H3/

PB

3H

2/P

B2

H1/

PB

1H

0/P

B0

H4/

PB

4P

B422

k

R62

PA

GE

DS

~

UP

/DN

2010

7D

15

MC

M62

06

0.1u

F

TX

2IN

RX

1OU

TR

X2O

UT+5V

D

U8 1

132

123

EX

TA

L

XT

AL

CK

OU

T

126

128

130

131

125

RE

SE

T

CK

PP

CA

PP

LOC

KP

INIT

4 3

TP

19

2MH

z

40M

Hz

RE

SE

T~

2

1

3

RS

T

MC

P13

0

.012

uF

C25

1U7 2

NC

/OE

GN

D

2.00

0MH

z

U5

0.1u

FC

11

+5V

D VD

D

VS

S

VD

D

OU

T

XT

AL_

OS

C_S

MT

+5V

D

+5V

D

+5V

D

121

120

119

+5V

D

22k

R26 53 50 51 47 46 41 44 42 43

DS

I/OS

0

DR

RD

WR

BN

BR

WT

DS

O52

MO

DA

/IRQ

AM

OD

B/IR

QB

MO

DC

/NM

I

DS

CK

/OS

1

3954 40 49

TIO

BS nc1

nc2

DS

P56

002F

C40

BG

22k

R35 22

k

R28

DS

ID

SO RD

~W

R~

+5V

D

DR

~D

SC

K

TP

3

TIO

O

2 4 6 8 10 12 14

1 3 5 7 9 11

n

J4 13 HE

AD

ER

_14

DS

ID

SO

DS

CK

DR

~+

5VD

RE

SE

T~

R29

10k

ALA

RM

DP

AD

PB

7 4

MH

1M

H2 X T

7 4

DB

9M-B

F_C

_OK 0.

1uF

C36

0.1u

FC

26

7 4

15

GN

D

9 3

0.1u

FC

108

C9

0.1u

F0.

1uF

C86

MA

X23

2CS

E

2 7

+5V

D+

5VD

1Q

1

3.3k

R27

PB

11

C21

0.1u

F0.

1uF

C69

0.1u

FC

62

3 2

330

R24

3 x

1uF

C14

PB

1P

B3

PB

5P

B7

PB

9

22k

R21

0.1u

FC

58C

480.

01uF

C52

0.01

uFC

560.

01uF

MM

BT

2222

+5V

D

22k

R19

22k

R17

4 6 8 10 12 142

22k

R18 A

UD

IO

J3 3 5 7 9 11 131

22k

R4

+5V

D

22k

R3

K E

HE

AD

ER

_14

0.1u

FC

150.

1uF

C31

0.01

uFC

12

22k

R7

22k

R9

22k

R8

D S

+5V

D

PB

0P

B2

PB

4P

B6

PB

8P

B10

0.00

1uFC2

C24

0.01

uFC

320.

01uF

0.01

uF0.

1uF

C22

C27

22k

R6

22k

R20

0.00

1uF

C20

9

MC

M62

06

Y0

Y1

Y2

Y3

Y4

Y5

Y6

Y7

74H

C13

8

U33

0.01

uFC

132

CS

~O

UT

2_IO

109

Magtrol Model DSP6001 Dynamometer Controller Appendix E: Schematics

AP

PE

ND

ICE

S

E.3 DSP DYNAMOMETER ANALOG I/OJ6

1

21 F

US

E

F1

HE

AD

ER

_SIP

2

A1

A2

A3

A4

A5J1

2

A7

A8

A9

A10

A11

A12

A13

A14A6

B1

B2

B3

B4

B5

B6

B7

B8

B9

B10

B11

B12

B13

B14

A15

AG

NDP

SC

_1

PS

C_2

ST

BY

_2

ST

BY

_1

+25

V

+25

V

+25

V

+25

V

ELE

C_1

ELE

C_2

TE

MP

_1

TE

MP

_2

VO

UT

_2

VO

UT

_1

CLU

TC

H

WF

LOW

1

WF

LOW

2

MH

1M

H2

MH

3M

H4

AG

ND

B15

D7

D1N

6294

A

D1

C53

0.1u

F

D1N

4004

2

AG

ND

J8

BN

C

1

2

DB

15F

-DU

AL

R_N

C

4 6

CO

M1

NC

1R

_NO

13 11 9

NO

1

CO

M2

NC

2N

O2

8

R_C

OM

VO

UT

_2

1+

CO

IL

U36

-CO

IL

3 2Q2

16

+25

V

1

D1N

914

MM

BT

2222

1kR45

D10

G5V

-2-H

1-D

C24

VO

UT

_1

+35

V

0.1

R49

1U2

32 TIP

141

S H

R72

1%681

+12

V

D1N

914

D3

AG

ND

R87

D6

BA

T54

S

-12V

R90

-12V

BA

T54

S

D9

+12

V

499

7

U32

B

V+8

+

C84V- 4

-

-12V

+12

V

1%

10M

R68

D1N

914

D4

681

R79

0.00

1uF

0.01

uFC90

AG

ND

5 6

0.1u

FC

106

0.1u

FC

81

AG

ND

1V

+8+12

V

V- 4 C10

7OP

A22

77U

AG

ND

1%6.98

k

R85

0.00

1uF 7

+3U32

A -2

AG

ND

5+

U27

B

1%

V+8

-12V +12

V

OP

A22

77U

TP

14T

P10

TP

5T

P4

SC

LKS

DO

UT

L/R

SC

K

1%

TP

6T

P7

TP

13

C82

6 5 0.1u

FC

73

AG

ND

7+12

V

V- 4V+

RE

F

SC

K

0.1u

F

AG

ND

AG

ND

-12V

ST

DS

RD

2MH

z

U38

A

+3

-281

74H

C14

2

+5V

D

0.1u

F

C76

RE

SE

T~

50R50

SR

DS

TD

L/R

CS

~A

D

SC

LKS

DO

UT

1uF

C71

C54

6

AG

ND

0.1u

F

2MH

z50R55

AG

ND

0.1u

F

C13

8

7 V+

+12

V

3 1 8

+ RG

1

U18

1 RG

1

RG

2

INA

122U

U29

16.9

k

R71

R57

51.1

k

499

+12

V

R53

499

BA

T54

S

D2

-12V 1

1J11

DIN

8

2 3 4 5 6 7 8

3 4 5 6 7 98 10M

H1

MH

2

2

C10

4OP

A22

77U

0.1u

F

1

C72

C79

OP

A22

77U

0.1u

FC

88

AG

ND

AG

ND

6-

3+

U27

A

2-

AG

ND

1%6.98

k

R88

V+8 V- 4

0.00

1uF

V- 4

-12V

-12V

+12

V

ALA

RM

R_N

OR

_NC

R_C

OM

1%6.98

k

R54

0.00

1uF

AG

ND

1%

C51

5

AG

ND0.1u

F

AG

ND

4V-

-12V

D5

2-

INA

122U

+12

V R89

499

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BA

T54

S

RE

F

D8

BA

T54

S

R91

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+12

V 499

4.99

k

R84

4.99

k1%R56A

GN

D

SP

EE

D_O

UT

TO

RQ

UE

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T

RG

2

RE

LAY

BR

AK

E_C

ON

TR

OL

RS

TB

+5V

A

23

2

VDD

0.1u

FC

83

AG

ND

16 17 18 19

LRC

INB

CK

IND

IND

OU

T

20

MC

MD

ML

C89

10uF

VCC214

C55

10 9

U25

0.1u

F

CIN

PL

CIN

NL

1 4 7 8

VIN

L

5 1215

VIN

R6

VR

EF

L

VR

EF

R

CIN

PR

CIN

NR

VO

UT

RV

OU

TL

VCC1

21

R95

XT

OC

LKIO 1%

24

13

DGND

AG

ND

0.1u

FC

139

1%R96

AGND1 3

AG

ND

11V

CO

M

4.99

k

AGND2

XT

I

C47

10uF

470p

FC

64

470p

FC

70C

78

C75

AG

ND

AG

ND

10uF

10uF

D11

BA

T54

S

AG

ND+

5VA

D12

AG

ND

+5V

A

23

V+8 V- 4

AG

ND

1U26

A+ -

+5V

A

OP

A22

77U

+5V

A

5+

AG

ND 6

-

8 4V+ V-

AG

ND

6 5

U17 RE

F

AG

ND C460.1u

FC

61

AG

ND0.1u

F

7U26

B

6AG

ND

7+ R

G1

V+

U34

+12

V

RE

F5 AG

ND

4-

V-

-12V

RG

2

3 1C

98

2

120p

F8

AD

620A

/AD

7 4

+3

-21 8

RG

1

RG

2

AD

620A

/AD

120p

FC

50

120p

FC

49

120p

FC

57V

+ V-

0.1u

FC

99

0.1u

FC

87 -12V

+12

V

0.1u

FC

85

OP

A22

77U

BA

T54

S AG

ND

+5V

A

7V

+8 V-

+12

V

C11

3

4 -12V

4700

pFOP

A22

77U

U35

B+

5

-6

R73

AG

ND

1%4.99

k

0.1u

FC

115

1%16.9

k

R83

V+8+

12V

AG

ND 0.

1uF

C95

V- 4 -12V

16.9

k

R86C11

4OP

A22

77U

4700

pFAG

ND

1

+3

AG

ND

-2

1%4.99

k

R82

U35

A

9

1uF

C77

AG

ND

3

VL+

+12

V SJ

RF

CO

MM

ON

I_O

UT

V_O

UT

VS

+5

16

14 156 7

MS

BT

RIM

LE DA

TA

CLK+

12V

11 12 1310

1uF

C63

PC

M56

P

9 PC

M56

P

AG

ND

8VL-

3

+12

V

-12V

VS

-1

AG

ND

16LOG

_CO

M

+12

V

SJ

RF

V_O

UT

VL+ 8I_O

UT

VL-

CO

MM

ON

VS

+

14 155 6 7

MS

B

CLK

LE DA

TA

VS

-1

2

TR

IM

LOG

_CO

M

U31

11 12 1310

U30

2

-12V

1%

1uF

10pF

C13

6S

DO

UT

SC

LK

50R93

1uF

C93

C13

7

10pF

SC

LK

SD

OU

T

R94

50

6 8

0.1u

FC

28

X4/

X1

CLK

7

LS70

84

2 VDD

+5V

D

A B

4 5U10

3VSS

100k

R36

1R

BIA

SU

P/D

N

7 9

TIO

0.1u

F

1Y

A B 1G 1C0

1C1

1C2

2Y

2G 2C0

2C1

2C2

2C3

1C3

14 2 1 6 5 4 3 15 10 11 12 13

74H

C15

3

C23

+5V

DU6

UP

/DN

CS

~D

A1

CS

~D

A2

C94 AG

ND

AG

ND

+25

VT

AC

H_B

F_C

_OK

1 2 3

J9

1%150k

R69

AG

ND

1%150k

R70

AG

ND

DP

AD

PB 1%500k

R80 1%500k

R81

1%

500k

R51

R521%

1%1%50

0k

AU

X_C

OM

AU

X_I

N

-25V

A_+

5VD

A_G

ND

TA

CH

_AIN

DE

X

TO

RQ

UE

_IN

TO

RQ

UE

_CO

M

5 6 7 8 9 10 11 13 14

MH

1M

H2

12

PA

RA

LLE

L14_

FE

MA

LE

4 6 8 10 12 142

BIT

E

J7 3 5 7 9 11 131

HE

AD

ER

_14

A_G

ND

TA

CH

_CR

OT_

SEN

S

4A

_CO

M

+25

VA

_CO

M

-25V

A_+

5VD

SP

AR

E

6 80.

1uF

C29

C68

5

C67

9

74H

C14

U38

C

74H

C14

U38

D

+5V

D

0.1u

FC

135

12U

38F

11

C66

13

C65

4U

38B

74H

C14

10

74H

C14

74H

C14

U38

E

10k

R61

10k

R60

TA

CH

_A

10k

TA

CH

_B

10k

R66 R

65

R64

+5V

D

+5V

D

+5V

D

10k

R59

10k

R58

3

10k

IND

EX

R63

+5V

D

10k

TA

CH

_C

120p

F

120p

F

120p

F

120p

F

120p

FC

91

120p

FC

92

80.6

kR

47

80.6

kR

46 T_S

EL1

T_S

EL0

AG

ND

AG

ND

4.99

k28 25 26 27 22

PC

M30

00

110

AP

PE

ND

IXA

PP

EN

DIC

ES

Appendix F: Additional Scale Factor Table

The Additional Scale Factor Table is the same as the M-TEST Defaults file, which contains default values for all parameters used in the testing of Magtrol Dynamometers and Torque Transducers. The M-TEST Defaults file is subject to change as ratings on Magtrol’s Motor Test Equipment change but the most recent version of this file can always be accessed from our Web site at www.magtrol.com/support/downloads.htm#mtestdefaults. Simply click the link if you are connected to the Internet or type the web address into your browser.

The file is saved in a tab delimited text format and can be accessed by Microsoft® Excel or LabVIEW™ programs, including M-TEST. If you need this information to configure your DSP6001 but do not have M-TEST 4.0 or 5.0, the text file can be imported into any spreadsheet or database program and the default values can be manually programed into the DSP6001 via the front panel menu system. Be sure to check the file frequently to make sure you have the most current data. Please feel free to contact our sales department at 1-716-668-5555, if you should have any questions or concerns.

111

Index

AAccessory Torque-Speed Output 12,37,80Additional Scale Factor 42,110Advanced Configuration 101Air Flow Alarm 56Alarm

Commands 69Operation 51Priority 52Relay 50

AlarmsAir Flow 56Electrical 60External 58Maximum Speed 53Maximum Torque 54Power 52Temperature 59

Alarm System 50AUX/TSC2 Connector 13,78Auxiliary Instrumentation

Setup 22,28,95Aux Setup Menu 90

BBaud Rate 67Bit Configurations 36Brake Fuse 12Bypass Capacitors 107

CCalibration 76

Procedure 76Schedule 76

ChannelsDynamometer 61

Command Set 69,101Communication

Commands 70Parameters 67

Com Setup Menu 91Configuration 15Contrast Settings 11Controls 8Controls and Buttons 8Cross Loop Function 35CTRL OUT 12

DDAC Output Offset and Gain 78Data Format 68

Data Sheet 2Decimal Point Check 81Derivative 40,43Digital Filters 38Dynamic Scale Effect 49Dynamometer Analog I/O 109Dynamometer Channel 61Dynamometer Configuration 18Dynamometer Configuration Menu 18Dynamometer DSP 108Dynamometer Memory 108Dynamometer Power Bypass Capacitors 107Dynamometer Setup Menu 93Dyno Setup Menu 18,92

EEarth Ground 14Eddy-Current Dynamometer 41

Setup 24,26,27,28,29,31,33,95,96,98Electrical Alarm 60EncoderExternal Alarm 58

FFeatures 1Flowcharts 88,101Front Panel 8,88Functions

Primary 88Saving 9Secondary 8,89

GGPIB

Installation 65Interface 14,65Primary Address 66

HHysteresis Dynamometer 41

Setup 19,20,22,24,94

IInputs 12

AUX/TSC2 13,78Dynamometer/TSC1 13,77Dynamometer Analog I/O 109Dynamometer Brake 12Supply 1 13,79Supply 2 14,79

Installation 15

112

Magtrol Model DSP6001 Dynamometer ControllerIndex

GPIB 65Integral 40,42

LLabVIEW Programming Examples 83Line Voltage 15

MMaximum Speed Alarm 53Maximum Torque Alarm 54MaxPower Setup Menu 92Max Speed Menu 90Memory 108Menus 88

Alarm Setup 100Aux Setup 21,90Com Setup 91Dynamometer Configuration 18,93Dyno Setup 18,92Encoder Setup 36,99Hysteresis Setup 19Main Menu 16MaxPower Setup 92Max Speed 90Power Units 89Torque Transducer Setup 21,94Torque Units 89

MiscellaneousCommands 75Configuration 106

OOpen Loop Control 64Outputs 12

Accessory Torque-Speed 12,37,80CTRL OUT 12Dynamometer Analog I/O 109

PPC Configuration 101PC Connection 67PC Control 101PID Loop 40,41PID Settings 40,43

Ramp Down 48Speed Control 46Torque Control 43

Powder Dynamometer 41Setup 24,26,27,28,29,31,33,97,98

Power Alarm 52Power Bypass Capacitors 107Power Cord 14Power Units 62,89Pre-Test Configuration 102

Programming 68Proportional Gain 40,42

RRamp

Commands 71Configuration 103

Ramp DownPID Settings 48

Rear Panel 12Remote Configuration 101Remote Control 101RS-232 Interface 14,66

SSaving Function 9Scale Factor 41

Speed DAC 37Torque DAC 37

Schematics 107Screen Saver 11Secondary Functions 8Self-Test 16Setup

Auxiliary Instrumentation 22,28,95Eddy-Current Dynamometer 24,26,27,28,29,31,33,95,96

,98Hysteresis Dynamometer 19,20,22,24,27,94Independent 29Powder Dynamometer 24,26,27,28,29,31,33,95,97,98Speed Encoder 36,99Tandem 31,33,96,97,98Torque/Speed DAC 37Torque Transducer 20,35,94

Setup Commands 72Simple Read 83Speed

Commands 74Configuration 104

Speed Check 80Speed Control 63

PID Settings 46Speed Correction 41Speed DAC Scale Factor 37Speed Encoder

Setup 36,99Speed Stabilized 85Status Display Messages 11Supply 1 Connector 13,79Supply 2 Connector 14,79

TTandem Setup 31,33,96,97,98Temperature Alarm 59

113

Magtrol Model DSP6001 Dynamometer Controller Index

Testing Instrumentation Setup 17Timeout 69Torque

Configuration 105Torque Commands 74Torque Control 62

PID Settings 43Torque DAC Scale Factor 37Torque Stabilized 84Torque Transducer

Setup 20,27,35,94Torque Transducer Setup 94Torque Units 62,89Troubleshooting 82TSC1 Offset and Gain 77TSC2 Offset and Gain 78

VVacuum Fluorescent Display 10

114

Service Information

RETURNING MAGTROL EQUIPMENT FOR REPAIR AND/OR CALIBRATION

Before returning equipment to Magtrol for repair and/or calibration, please visit Magtrol’s Web site at http://www.magtrol.com/support/rma.htm to begin the Return Material Authorization (RMA) process. Depending on where the equipment is located and which unit(s) will be returned, you will be directed to either ship your equipment back to Magtrol, Inc. in the United States or Magtrol SA in Switzerland.

Returning Equipment to Magtrol, Inc. (United States)

When returning equipment to Magtrol, Inc.’s factory in the United States for repair and/or calibration, a completed Return Material Authorization (RMA) form is required.

1. Visit Magtrol’s Web site at http://www.magtrol.com/support/rma.htm to begin the RMA process.

2. Complete the RMA form online and submit.

3. An RMA number will be issued to you via e-mail. Include this number on all return documentation.

4. Ship your equipment to: MAGTROL, INC. 70 Gardenville Parkway Buffalo, NY 14224 Attn: Repair Department

5. After Magtrol’s Repair Department receives and analyzes your equipment, a quotation listing all the necessary parts and labor costs, if any, will be faxed or e-mailed to you.

6. After receiving your repair estimate, provide Magtrol with a P.O. number as soon as possible. A purchase order confirming the cost quoted is required before your equipment can be returned.

Returning Equipment to Magtrol SA (Switzerland)

If you are directed to ship your equipment to Switzerland, no RMA form/number is required. Just send your equipment directly to Magtrol SA in Switzerland and follow these shipment instructions:

1. Ship your equipment to: MAGTROL SA After Sales Service Route de Montena 77 1728 Rossens / Fribourg Switzerland

VAT No: 485 572

2. Pleaseuseourforwarder:TNT•1-800-558-5555•AccountNo154033 Only ship ECONOMIC way (3 days max. within Europe)

3. Include the following documents with your equipment:

• DeliverynotewithMagtrolSA’saddress(aslistedabove)

• Threeproformainvoiceswith:

• YourVATnumber • Value-forcustomspurposesonly • Descriptionofreturnedgoods • Originofthegoods(ingeneral,Switzerland) • Noticedfailures

4. A cost estimate for repair will be sent to you as soon as the goods have been analyzed. If the repair charges do not exceed 25% the price of a new unit, the repair or calibration will be completed without requiring prior customer authorization.

www.magtrol.comTesting, Measurement and Control of Torque-Speed-Power • Load-Force-Weight • Tension • Displacement

MAGTROL INC70 Gardenville ParkwayBuffalo, New York 14224 USAPhone: +1 716 668 5555Fax: +1 716 668 8705E-mail: [email protected]

MAGTROL SARoute de Montena 771728 Rossens / Fribourg, SwitzerlandPhone: +41 (0)26 407 3000Fax: +41 (0)26 407 3001E-mail: [email protected]

Subsidiaries in:Germany • France

China • India

Worldwide Network of Sales Agents

Documents

Model DSP6001 User's Manual - magtrol.com · i 1. Make sure that all Magtrol dynamometers and electronic products are earth-grounded, to ensure personal safety and proper operation